GESTRA TRAPtest VKP 30 User manual

TRAP test VKP 30
Installation Instructions
Steam Trap Monitoring, Recording
and Evaluation System

Contents
Important Notes
Proper use........................................................................................................................... 3
Safety note .......................................................................................................................... 3
Danger ................................................................................................................................ 3
Page
2
Explanatory Notes
Scope of supply................................................................................................................... 4
Description .......................................................................................................................... 4
Notes................................................................................................................................... 5
Technical data..................................................................................................................... 5,6
Recharging storage batteries .............................................................................................. 6
Replacing storage batteries / lithium back-up battery ......................................................... 6
Installing and Starting the TRAPtest Software
Installing the software .........................................................................................................7
Starting the TRAPtest program .......................................................................................... 7
Menu Items of theTRAPtest Software
Extras ..................................................................................................................................7,8
Test objects......................................................................................................................... 8
Test instructions .................................................................................................................. 8
Terminal .............................................................................................................................. 8
Online Documentation......................................................................................................... 8
Connecting and Commissioning theTerminal
Connecting the terminal to a PC ......................................................................................... 9
Connecting the measuring transducer to a PC ................................................................... 9
Commissioning the terminal ...............................................................................................9,10
Checking SteamTraps
Preparation.......................................................................................................................... 11
Test .................................................................................................................................. 11,12
Note..................................................................................................................................... 10
Annex
Declaration of conformity..................................................................................................... 12

Important Notes
Proper use
Use TRAPtest VKP 30 only for testing steam traps.
Safety Note
The equipment must only be installed by qualified staff.
Qualified staff are those persons who – through adequate training in electrical engineering, the
use and application of safety equipment in accordance with regulations concerning electrical
safety systems, and first aid & accident prevention – have achieved a recognised level of
competence appropriate to the installation and commissioning of this device.
The measuring transducer VKPS 30 must not make contact with any live part –
danger of electric shock.
Be careful when handling the equipment – danger of injuries caused by sharp-edged
tip of measuring transducer.
Danger
3

Explanatory Notes
Scope of Supply
The service case of the TRAPtest VKP 30 contains:
1 Hand-held terminal VKPN 30
1 Measuring transducer VKPS 30
1 Bag for VKPN 30
1 Bag for VKPS 30
1 Lithium back-up battery (installed in VKPN 30) for saving data in the event of a power
failure
4 Storage batteries (installed in VKPN 30)
1 Adaptor VKPA 30 (incl. battery charger and connecting cable for VKPN 30)
1 Power supply unit
1 Serial cable (for connecting the adaptor to the PC)
1 Adaptor for the serial cable
1 Service case
1 VKP 30 Software on CD-ROM
1 Installation manual
Description
Thesteamtrap monitoring,recording andevaluation systemVKP 30consists ofthe measuring
transducerVKPS30,theterminalVKPN30andthecorrespondingsoftwarefordatamanagement
by PC.
With the aid of the VKP 30 all types and makes of steam traps can be checked for loss of live
steam, thus evaluating their performance.All test results determined by the hand-held terminal
VKPN 30 can be easily stored, evaluated and managed using a PC.
The testing and diagnostic system detects and evaluates ultrasonic vibrations of steam traps
which are caused by the flow of fluid/steam through the trap. These ultrasonic vibrations are
sensedbypressingthetipofthemeasuringtransducerVKPS30ontoaspecifictrapbodypoint,
which depends on the trap type and make. The ultrasonic vibrations are converted by the
measuring transducer into electrical pulses and transmitted via cable as digital signals to the
terminal VKPN 30. The recorded sound curves are evaluated by the terminal VKPN 30 using
empirical limit sound values (LV) characteristic of the particular trap type. For thermostatic
(bimetallicandmembrane),ballfloatandinvertedbucketsteamtrapsthelimitsoundvaluesare
dictated by the testing and diagnostic system.
Thesignalsreceivedduringthetestarerepresentedontheterminal’sVDUintheformofagraph.
All plotted curves of a steam trap as well as the complete survey history (numeric test results
and respective evaluations thereof) can be stored and printed.
For more information on the system refer to the Online Documentation of the TRAPtest
software.
To print the Online Documentation use the WORD file “Documentation.doc” from the directory
“<Drive>:\GESTRA\VKP”.
4

Explanatory Notes
Notes
■Please observe the full system description in the online documentation of the
TRAPtest main menu.
To print the Online Documentation use the WORD file “Documentation.doc”
from the directory “<Drive>:\GESTRA\VKP”.
■The TRAPtest program and the online documentation are at present only
available inENGLISHandGERMAN.Shouldthiscauseanyproblemsplease
contact our head office or your local repesentative.
■Replace the back-up battery type 2032 installed in the terminal VKPN 30 once a
year.
■Donotoperatehand-heldterminalVKPN30 withprimarycells.Userechargeable
1.2 V storage batteries type NiMH with a min. capacity of 1100 mAh.
■Use measuring transducer VKPS 30 only for sensing ultrasonic vibrations at
steam trap bodies.
Technical Data
5
System Requirements
Windows 95, Windows 98, Windows NT
CD-ROM drive
80 MB of free hard-disk space
Test Duration
20 sec.
Hand-Held Terminal VKPN 30
Plastic case with illuminated visual display and a 7-key membrane keypad.
Storage battery compartment at the underside of the device.
Two plug connections at the front face (for connecting measuring transducer VKPS 30 and
adaptor VKPA 30)
Protection: IP 65
Max. admissible service temperature: 70 °C
Min. admissible service temperature: 0 °C
Memory capacity sufficient for approx. 450 steam traps
Power Supply
Power is supplied by four identical NiMH Mignon AA-size 1.2 V 1400 mAh storage batteries,
or by the power supply unit that comes with the VKP 30.
Use only rechargeable 1.2 nickel metal hybride batteries with a min. capacity of 1100 mAh.
Do not use primary cells!

Explanatory Notes
Technical Data continued
Recharging Storage Batteries
Plug the power supply unit into the adaptor VKPA 30 and then into an earthed mains socket.
The red and green LEDs of the adaptor are illuminated (green = power on, red = recharging).
The recharging of a completely discharged storage battery takes 16 hours.
Replacing Storage Batteries / Back-Up Battery
To replace the storage batteries remove the battery compartment cover. To replace the lithium
back-upbattery(buttoncelltype2032)undotheeightscrewsattherearoftheterminalandopen
the housing.
Do not remove the storage batteries before replacing the back-up battery (data loss). Be
careful when taking apart the two housing halves. Make sure not to damage the cable
connection.
Slightlyliftthebracketofthebatterycompartmentandleveroutthebatteryusinga screwdriver.
6
Measuring Transducer VKPS 30
Power is supplied to the measuring transducer by the storage batteries of the terminal.
Adaptor VKPA 30
The adaptor connects the terminal to the PC. When the power supply unit is connected the
storage batteries installed in the terminal VKPN 30 will be recharged.
Power Supply Unit
230 V/50 Hz (other ratings on request)
Output: 12 V
Weight
Case with content approx. 6 kg
Dimensions
Case: 540 x 360 x 140 mm
Bag: 140 x 100 x 250 mm
Measuring transducer VKPS 30: 225 x 140 x 30 mmm
(Length x Width x Height)

Installing and Starting theTRAPtest Software
Exit all open applications. Insert the TRAPtest CD in your CR-ROM drive, the installation
program starts automatically. Follow the on-screen prompts. The set-up program creates the
folder VPK 30 in the program group GESTRA.
Installing Software
TRAPtest Program
To start the program, click the START button on the Windows taskbar, point to Programs,and
then click TRAPtest. The main menu window appears.
To close the program, click the QUIT button in the main menu.
EXTRAS
The menu EXTRAS consists of the following items:
MANUFACTURER ORGANIZE COMPANY LANGUAGE
LIMIT VALUES ABOUT IMPORT
INTERFACE TESTER LOAD UPDATE
Under the menu item MANUFACTURER you can take down the particulars of the steam trap
manufacturers whose steam traps are installed in your plant. The entries are then listed in the
menuTestObjectsandcanbeselected.Werecommendtoenterthecorrespondingdatabefore
starting off with the first test object.
Under the menu item TESTER you can enter the name of your employees who are entrusted
with the task of checking the steam trap. The entries are then listed in the menu Test Objects
and can be selected. We recommend to enter the corresponding data before starting off with
the first test job.
Under the menu item LIMIT VALUES you can change the limit sound values preset by the
system (consultation with GESTRA recommended).
Under the menu item LANGUAGE you can select the language of your country.
Under the menu item INTERFACE you can select the port (COM 1, COM 2).
Under the menu item IMPORT you can import data records from a previous version (VKP 20).
Under the menu item ORGANIZE COMPANY you can enter the corporate names of the
operators or subdivisions of a company. The data entered here serve as key field to identify a
particular record and its occurence in the database.
Please note: When deleting an entry the related data record stored under this entry will
also be cleared completely.
Thecurrentlyselectedcorporatenames/subdivisionsare,forinstance,theheadersofprintouts
and windows.
Under the menu item LOAD UPDATE you can load the latest software version for the terminal
VKPN 30.
Under the menu item ABOUT you will find the address of the producer, the version number of
the TRAPtest program and the name of the currently selected company.
Menu Items of theTRAPtest Software
7

TEST OBJECTS
Menu Items of theTRAPtest Software continued
In this menu all steam trap data and related installation information can be acquired and
processed. You can exchange steam trap data and modify or delete data records. All data
including the test results can be processed, displayed or printed by defining filter criteria.
TEST INSTRUCTIONS
In this menu you can compile and process test instructions for the traps to be checked. All test
results can be displayed and printed out. Clicking the mouse button shows/prints the repair list
containing all traps of a test instruction evaluated as defective. For each test instruction the
systemmakesastatisticalstudyofthenumberoftrapschecked,notcheckedandtobechecked
as well as the number and percentage of defective traps.
HAND-HELD TERMINAL
In this menu the dialogue with and administration of the terminal takes place. Test instructions
are exported to the terminal and test results are imported from the terminal. Test instructions
stored in the terminal can be deleted.
ONLINE DOCUMENTATION
In this menu you will find a detailed functional description of the monitoring, recording and
evaluation system for steam traps TRAPtest VKP 30.
The online documentation is at present only available in ENGLISH and GERMAN. Should this
cause any problems please contact our head office or your local repesentative.
8

Connecting and Commissioning theTerminal
Connecting theTerminal to a PC
Plug the power supply unit into the adaptorVKPA 30, and then into an earthed mains socket.
The red and green LEDs of the adaptor are illuminated (green = power on, red = charging).
Connect the adaptor cable of the VKPA 30 to the terminal VKPN 30.
Use the supplied serial cable to connect the adaptor to the PC.Then choose the selected PC
port (COM 1 or COM 2) in theTRAPtest on-screen menu EXTRAS/ Interface and confirm your
entry.
Connecting the MeasuringTransducer to a PC
ToconnectthemeasuringtransducerVKPS30totheterminal,plugthe connectingcableofthe
measuring transducer into the right jack of the terminal VKPN 30.
Commissioning theTerminal
To start the terminal VKPN 30, press the START key for approx.5 seconds.
The dialogue box “load VKP 30” pops up and then the front page of the TRAPtest program appears.
Press the ENTER key to call up the main menu on the terminal.
9

Commissioning theTerminal continued
Connecting and Commissioning theTerminal
The main menu consists of the following items: TEST
TEST MEASUREMENT
DATA EXCHANGE
QUIT
Under the menu item TEST you can check steam traps for loss of live steam. The respective data
records and test instructions must have been previously created on the PC. The test results will be
evaluated right after each trap test by the terminal.
Under the menu item TEST MEASUREMENT you can check and evaluate steam traps for loss of live
steam without prior creation of data records and preparation of test instructions. The test results are
only stored up till the next measurement.
Under the menu item DATA EXCHANGE information is exchanged between the PC and the terminal.
The data stored in the terminal can be organized on the PC.Test instructions are transferred from the
PC to the terminal and test results are sent back from the terminal to the PC. The test instructions
stored on the terminal can be deleted on the PC.
Use or to select (mark) the menu item in question and then press the ENTER key .
To switch off the equipment, choose menu item QUIT.
For more inforamtion refer to the Online Documentation of theTRAPtest software.
Switch on
Confirm
Go back
Cursor
10

Preparation
Checking SteamTraps
UseVKP 30 to check and evaluate all types and makes of steam traps for loss of live steam.
After starting the terminal VKPN 30, select menu item TEST.
For more information refer to the Online Documentation of the TRAPtest software.
To print the Online Documentation use the WORD file “Documentation.doc” from the directory
“<Drive>:\GESTRA\VKP”.
Proceed as described in the Online Documentation.
Tocheckconventionalthermostatic steamtraps(withbimetalliccontrol ormembraneregulators),
gently press the tip of the measuring transducer perpendicular to the trap surface onto the
passage between cover and cover flange (see illustrations).
Test
To check float traps, gently press the tip of the measuring transducer perpendicular to the trap
surface onto the highest point of the cover.
11

To check GESTRA RHOMBUSline steam traps use the two contact points provided at the
edge of the name plate on the cover. Gently press the tip of the measuring transducer
perpendicular to the surface into the respective dimple.
Test continued
Checking SteamTraps
Important
If steam traps of the same type are tested take care that the tip of the measuring
transducer is always applied at the same point of the trap body in order to be able
to compare the results obtained and also to discover changes when repeating the
test.
We hereby declare that the equipment VKP 30 conforms to the following European guidelines:
nLV guideline 73/23/EWG version 93/68/EWG
nEMC guideline 89/336/EWG version 93/68/EWG
which are based on the following harmonised standards:
nLV standard EN 60947-5-1: 1991
nEMC standard EN 50 081-2, EN 50 082-2
Thisdeclarationisnolongervalidifmodificationsare madetotheequipment withoutconsultation
with us.
Bremen, 1st January 2000
GESTRA GmbH Dipl.-Ing. Uwe Bledschun
Dr. Anno Krautwald
Declaration of Conformity
Annex
12

810657-00/401 .© 2001 GESTRA GmbH .Bremen .Printed in Germany
Christian Schmidt, 24.02.2000