Spirax Sarco STAPs User manual

IM-P014-23 EMM Issue 4 1
1. Safety information
2. General product information
3. Installation of head
4. Spare parts
5. Certication and approvals
6. Technical data
© Copyright 2019
Printed in GB
0142050/4
STAPS
Wireless Head Unit
for ISA100.11a applications
Quick Installation Guide
IM-P014-23
EMM Issue 4

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Software copyright
Certain computer programs contained in this product [or device] were developed by Spirax-Sarco
Limited ('the Work(s)').
Copyright © Spirax-Sarco Limited 2019
All Rights Reserved
Spirax-Sarco Limited grants the legal user of this product (or device) the right to use the Work(s)
solely within the scope of the legitimate operation of the product (or device). No other right is
granted under this licence. In particular and without prejudice to the generality of the foregoing,
the Work(s) may not be used, sold, licensed, transferred, copied or reproduced in whole or in part
or in any manner or form other than as expressly granted here without the prior written consent of
Spirax-Sarco Limited.
Open source software
This product uses open source software that is based on Freertos general public license (GPL), etc.
Terms and conditions of GPL
For details of GPL, visit the website: http://www.freertos.org/a00114.html
Operation guarantee
According to the terms and conditions of the license shown above, we do not guarantee the operation
of open source software itself.
Information on respective open source license software
For module names and source codes of open source software that is used in this product, please
contact us.

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Safe operation of this unit can only be guaranteed if it is properly installed, commissioned and
maintained by a qualified person (see Section 1.11) in compliance with the operating instructions.
General installation and safety instructions for pipeline and plant construction, as well as the
proper use of tools and safety equipment must also be complied with.
Registered Address - Spirax-Sarco Limited ,
Charlton House,
Charlton Kings,
Cheltenham,
Gloucestershire,
UK,
GL53 8ER
The product is designed and constructed to withstand the forces encountered during normal use.
Use of the product for any other purpose, or failure to install the product in accordance with these
Installation and Maintenance Instructions, could cause damage to the product, will invalidate the
marking, and may cause injury or fatality to personnel.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended use / application.
i) The product has been specifically designed for use on saturated steam systems.
ii) Check material suitability, pressure and temperature and their maximum and minimum values.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be induced by
any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1. Safety information

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1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed action
(e.g. closing isolation valves, electrical isolation) put any other part of the system or any
personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering ineffective of
controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid
system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume
that the system has depressurised even when the pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns and consider
whether protective clothing (including safety glasses) is required.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables available. Use only
genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and / or others in the vicinity require any protective clothing to protect against
the hazards of, for example, chemicals, high / low temperature, radiation, noise, falling objects,
and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person. Installation and
operating personnel should be trained in the correct use of the product according to the Installation
and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where there is no such
system, it is recommended that a responsible person should know what work is going on and,
where necessary, arrange to have an assistant whose primary responsibility is safety.
Post 'warning notices' if necessary.

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1.12 Handling
Manual handling of large and / or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the maximum permitted
operating conditions the surface temperature of some products may reach temperatures of 427 °C
(800 °F).
Many products are not self-draining. Take due care when dismantling or removing the product from
an installation (refer to 'Maintenance instructions').
1.14 Freezing
This product does not contain fluid that will freeze, however lower temperatures will affect the
product performance. Do not subject the product to temperatures below the stated minimum.
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken. The product
should be recycled in line with local legislation. Special attention should be paid to the battery,
see Section 1.17.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law, when
returning products to Spirax Sarco they must provide information on any hazards and the
precautions to be taken due to contamination residues or mechanical damage which may present
a health, safety or environmental risk. This information must be provided in writing including
Health and Safety data sheets relating to any substances identified as hazardous or potentially
hazardous.Refer to Section 1.17 with regards to shipping / returning of the lithium batteries.

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1.17 Bat te r y
The Head unit is powered by a Lithium battery (Tadiran SL-2880).
Handling considerations:
- Do not crush, pierce, short (+) and (-) battery terminals with conductive (i.e. metal) goods.
- Do not directly heat or solder.
- Do not throw into a fire.
- Do not mix batteries of different types and brands.
- Do not mix new and used batteries.
- Keep batteries in non-conductive (i.e. plastic) trays.
- Do not subject the battery to temperatures above 100 °C
Storage
Store in a cool (preferably below 30 °C), dry, clean and well-ventilated area.
Environmental consideration
As with any battery, local environmental regulations must be adhered to with regard to disposal of
spent batteries. Special attention must be paid not to mix with other types of batteries.
Battery hazards remain even when the cells are discharged.
Shipping considerations
Transport of Lithium batteries is regulated by many authorities. i.e.:
- ADR (European Ground Transportation),
- IATA (International Air Transport Association),
- ICAO (International Civil Aviation Organisation) and the Regulations concerning the
International Carriage of Dangerous Goods by Rail (Intergovernmental Organisation for
International Carriage by Rail).
It is the responsibility of the shipper to ensure that these regulations are followed.
1.18 Use of non genuine components or spare parts
This product is certified by a number of health and safety regulatory bodies for health and safety
and environmental purposes. To maintain the approvals only genuine components and spare parts
must be used. This includes consumable items such as the Tadiran battery and power supplies.

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Fig. 1
2.1 General description
The STAPS wireless steam trap monitoring system has been designed to efficiently monitor and evaluate
steam trap operation. It surveys the operation of the steam trap at regular intervals and identifies poor
performance that can cause reduced plant efficiency and increased energy consumption. It can diagnose
both failed-open steam traps that leak live steam, and those that have failed-closed or are blocked, resulting
in waterlogging, leading to plant damage, product spoilage and health and safety concerns.
Using non-intrusive installation technology combined with ISA100.11a 2.4 GHz wireless network, it is an
id ea l s o l u t i on fo r s te a m t r ap mo ni to r in g. I t i s s ui t a b le fo r u se wi th al l t y p e s o f s te am tr ap an d c a n b e c o nn ec te d
to pipework up to 100 mm (4"), via an adjustable clamp.
How does it work?
A head unit assembly mounted on the pipe upstream of the trap
to be monitored 'listens' to the sound signature of the trap in
operation. This sound signature is categorised and the trap
c o n d i t i o n a n d s t e a m l o s s a r e t r a n s m i t t e d v i a 2 . 4 G H z ( I S A1 0 0 .11 a)
wireless network. The trap condition and steam loss data is
available via the ISA100.11a network.
Each STAPS head unit assembly is powered by a long life
Lithium batter y (typic al bat ter y life of over 3 years). The devic e
is ISA100.11a compliant, and is capable of seamlessly joining
and being part of existing and new ISA100.11a compliant
n e t w o r ks . I t i s c a p a b l e o f a c t i n g a s a n I S A1 0 0 .11 a r o u t i n g d e v i c e
if and when required to extend the radius of the network, but
this will have an effect on the expected lifetime of the battery.
To maximise battery lifetime, the device should be set to act
as an ISA100.11a I/0 (end node) only device with the routing
functionality turned off.
The steam trap data of each device is passed over to the
ISA100.11a network Manager via a backbone router (Access
Point), and is made available to the backbone network via
interface(s) of the ISA100.11a network Gateway.
2.2 STAPS head unit assembly
The STAPS head unit includes the head unit and the sensor and
clamp that must be connected to the steam pipe upstream of the
steam trap that it is monitoring. The pipe clamp is available in
four sizes to suit: ½" - 1¼", 1½", 2" - 2½" and 3" - 4".
2. General product information

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Fig. 1 Fig. 2
Slot used for size of pipe:
½"
¾"
1"
1¼"
- 1 off head and sensor assembly, including the head unit and sensor.
3. Installation of the head unit assembly
Note: Before actioning any installation observe the 'Safety information' in Section 1.
The STAPS sensor includes the following parts:

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- 1 off lower clamp with 'T' bolt and wing nut.
Size ½" - 1¼"
Larger sizes use a top
clamp with jubilee clips.
Size 1½" to 4"
- A Tadiran SL-2880 3.6 V battery will be required to power each head, and is supplied
loose within the box.
Fig. 3
Fig. 4
Fig. 6
Clamp for use with a Spirax Sarco STS17 or
STS17.2 compact pipeline steam trapping station.
Fig. 5
-The weather - The head unit is IP66 rated.
-Wireless signal obstructions - Will adjacent buildings, pipework or other objects obstruct the wireless
signal from reaching the nearest access point.
-Interference - Is there any electrical or radio interference that may affect the performance of the STAPS
head unit.
-Access - Is there sufficient access to the head to change the batteries for maintenance?
-Installation - Is there sufficient room at the sensor at the top for the head to be mounted on the pipe?
-Lagging - Ensure that any pipe lagging in the area where the STAPS head is to be fitted is removed
before fitting. DO NOT re-lag the STAPS head unit, including the clamp and stem.

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3.1 Fitting the battery to the sensor head
The head unit assembly requires a Tadiran SL-2880 3.6 V battery to function.
Note: The head unit needs to be powered to be commissioned. However if the complete 'system' (receiver
and DCS) is not in service, the battery should be removed until required. Failure to do so will considerably
reduce battery life.
3.1.1 Unscrew the head cover retaining screw.
Fig. 7

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Fig. 8
Fig. 9
-Lift housing lid.
3.1.2 Turn head cover anticlockwise to unscrew.

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Fig. 10
3.1.3 Unscrew EMC shield screws.
Fig. 11
-Lift EMC shield.

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3.1.4 Ensure all packaging is removed and fit
battery into holder in the head unit. Ensure that
the battery is in the correct orientation as per the
orientation marker (+ to top).
Note: Only use a Tadiran SL-2880 Lithium Thionyl
Chloride 3.6 V battery.
It is normal for the LED to light momentarily when the
battery is fitted (see Section 3.1.7 for information on
the operation of the LED).
3.1.5 Refit the EMC shield and tighten screws.
3.1.6 Refit the cover and retaining screw. Check that the 'O' ring seal is in good condition before refitting
the cover. Make sure that Molykote 111 Compound is applied to the threads to ensure a air tight seal and the
the cover is correctly seated in place.
3.1.7 Button and LED Function
The button (Top left - Figure 13) will perform a number of functions dependent on the length of time it is held
and whether it is pressed before the battery is inserted.
Fig. 12
Fig. 13
Infrared
provisioning
port
Button

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The LED response – number of flashes, follows the following pattern for each status that it is reporting; 1
flash is bad, 3 flashes are good.
Time
pressed Function Action
< 0.2 s None
0.2 - 5 s Display
status
The LED flashes green rapidly whilst the button is pressed.
When the button is released the LED flashes red in sequence to indicate trap
condition, battery status and RSSI.
Trap condition 1 flash: Leak
2 flashes: Warning
3 flashes: Good
Battery Status 1 flash: Replace
2 flashes: Warning
3 flashes: Good
RSSI 1 flash: <=-80 dBm
2 flashes: >-80, <=-60 dBm
3 flashes: >-60 dBm
Press and hold the button before fitting the battery.
Note: There will be a small delay before the LED begins to flash green.
5 - 10 s Remove
provisioning
If the button continues to be pressed the LED continues to flash green. The
erase occurs after the button is released. The LED flashes red whilst the
provisioning is being removed.
15 - 20 s
Reset to
factory
default
If the button continues to be pressed the LED continues to flash green.
The reset occurs after the button is released.
The LED flashes red whilst the reset to factory defaults is being applied.
> 20 s None

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Fig. 15
-Screw in knurled antenna nut.
3.2 Attaching the antenna
Fig. 14
-Align the antenna pin with the antenna adaptor jack.
Fig. 16
-Align antenna vertically and ensure the antenna
nut is fully tightened.

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3.2.1 Fitting a remote mounted antenna
Where the head unit is installed in an area with poor radio reception, an extension cable of up to 3 m length
may be used to re-site the antenna and improve reception.
Take the extension cable and attach one end to the antenna adaptor on the head enclosure as shown in
Figure 17.
Mount the alternative antenna in the desired position using the pole clamp supplied with the antenna as
shown in Figure 18.
Take the loose end of the extension cable and attach to the end of the antenna as shown in Figure 19.
Fig. 17
Fig. 18 Fig. 19

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0
10 20
30 40
50
60 70
-20
427
400
350
300
250
200
150
100
50
0
-20
3.3 Fitting the heat shields
Where process and ambient temperatures exceed the limits of the standard head unit, heat shields must be
fitted. See the chart below.
Refer to Section 3.3.1 for the correct installation of the heat shields, taking particular notice of the orientation
shown in Figure 31.
Process temperature °C
Ambient temperature °C
Do not use in this region
Standard STAPS head
Heat shield kit must be fitted

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Fig. 20
Upper (larger) heat shield
Lower (smaller) heat shield
The heat shield kit consists of two individual
heat shields, upper and lower. Both heat
shields must be fitted to achieve the optimum heat
dissipation.

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3.3.1 How to install the heat shields
Remove the fixing clamp retaining nut, ensure the sensor stem does not rotate by using a 16 mm spanner
on the flats provided as per Figure 21 and remove the nut as per Figure 22. Failure to do so may affect the
factory set loading of the sensor.
Fig. 21
Fig. 22
Hold stem base with spanner
using the 16 mm flats on the stem.