TM2 Manual (M) (2.2)012492 Trap Man. Computerized Steam Management System Tall TY ae [ono Copyright 1992 by TLV Co., Ltd. ey NK (lhe reservedTM2 Manual (M) (2.2)012492 TLV. We would like to take this opportunity to thank you for purchasing the TrapMan Computerized Steam Trap Management System. TrapMan greatly increases the accuracy and efficiency of steam trap inspection and diagnosis and makes possible computerized collection and analysis of the results. This is made possible by a diagnostic device containing TLV’s steam trap diagnostic technology and software programmed with TLV's trap management expertise. This manual is a complete guide on the proper use of TrapMan. It begins with a description of the various components of the TM2 diagnostic device and then proceeds to the procedures for actual measurement. In order to properly use TrapMan, be sure to read this manual together with the PS1 Software User's Guide. This manual should be retained for future reference.TM2 Manual (M) (2.2)012492 — TABLE OF CONTENTS— ITEM PAGE Accessories Advantages of Using TM2 2 Features 2.0.2.6... cece eee eee Redeem cece teen een ee eee eeteneeeeeas 3 Function Keys Operation .........000000000sseeeteeeeseeetetteereeees 5 TM2 Procedural Flow Chart 6 Start of Operation 7 1. Connecting the Probe 2. Turning on Power ... 3. Clearing the Internal Memory 4. Setting the Internal Clock . 5. Entering the Area Number and Trap Number . 6. Selecting the Model Fundamentals of Measurement ............... 3 1. Principle of Judging Steam Leakage .... B 2. Principle of LOW TEMP Judgment 14 Model Name Input Procedure 15 1. Individual Entries by Using the Code Book . 15 2. Registration of Models . 7 Trap Measurement 20 1. Verifying TM2 Display Information 20 2. Trap Measurement Using the Probe 20 3. Proper Method of Holding the Probe .............ccccceseeee. 22 4, Automatic Evaluation 23 5, Judgement Procedure, @ . 28 6. When Modification of the Evaluation Results Required 30 7. Consecutive Measurements cee 3TM2 Manual (M) (2:2)012492 — TABLE OF CONTENTS— (Cont'd) ITEM PAGE Review of Summary Data ........0.00.cc00eeeeeeeeeeeeeeeeeeee ones 32 Data Transfer . 35 Display of Error Messages ........ ce eeeees ceteeeeeeeeee 36 Malfunction Diagnosis 38 Charging Procedure ..........0005 39 Replacement of Battery Pack .............0005 4 Use of the Protective Jacket and Belt Pouches ........00.000000 2 42 Precautions ......... 44 1. Locations Not Suitable for TM2 Use or Storage 44 2. Handling of TM2 Unit 45 3. Handling the Probe ............ wees cee eec eect eees 46 4, Connecting the Coiled Cable 47 5, Handle the AC Adaptor/Charger with Care . 47 6. Immediately After Purchase or After an Extended Period of Non-Usage . 48 7. Before Storing TM2 .. 48 Specifications .. 49 Dimensions ..........00eeeeeeeeeeeeeeeeeeeeeeteeeeeeeeeeeeteeeenes 50 Product Warranty ..........cse0eeeeeeeee ‘ ‘ 53TM2 Manual (M) (2:2)012492 Accessories The following accessories are included with this product. Please check to make sure all the items listed are included before using. 1) TM2 unit (in protective jacket) 2) TM2 probe 3) Coiled cable 4) Belt Pouches for TM2 unit and probe 5) Wrist strap 6) 21cm. metal file 7) AC adaptor/charger 8) Interface cable 9) Carrying case 10) Trap Man manuals: © TM2 Operating Manual (this manual) © PS1 Software User's Guide © PS1 software (for use with personal computer) © TM2 Type Code BookTM2 Manual (M) (2:2)012492 Advantages of Using TM2 1) Wide Range of Functions © Checks and automatically evaluates the operating condition of steam traps. * Capable of storing evaluation data for up to 800 steam traps. (A back up battery is provided to prevent data loss when the power is turned off.) © Steam trap type can be easily input * Calculates the number of inspected traps, number of faulty traps, and malfunction rate, etc. © The data can be transferred to a personal computer for more precise data processing such as a steam trap management log and aggregate analysis. 2) Easy Operation ¢ simple key operation. © Measurement is as simple as placing the probe tip on the inlet of the steam trap for 15 seconds © The LED on the back of the probe flashes to indicate measurement in progress and the completion of measurement. 3) Compact and lightweight for convenient portability © The total weight is approximately 1125g. and the probe weight is less than 500g. ® The main unit fits in the palm of your hand, permitting extended operation without fatigue. © The unit can be attached to your belt in the specially designed cases provided, to prevent it from coming into contact with piping or being dropped 4) Illuminated display * Clearly readable display, even in the dark. 5) Up to approximately 8 hours of continuous measurement on a 6 hour chargeFeatures a) (3) Probe connector TM2 Manual (M) (2.2)012492 Connects the coiled cable to the probe. LCD Display Indicates the number of the traps being measured, evaluation results, etc. * TLV Trap Man TM2 on l uci or Power switch (ON,OFF switches) Switch power on or off. Light switch Switches on and off to illuminate the display. Function keys Various functions are assigned to these keys. Trap type input keys Used when entering the type of steam trap to be tested. Numeric keys Used to enter the trap number, type, etc. SHIFT key Used to enter alphabetic characters for the area number and trap number. ENT key Used to enter alphabetic characters, numbers, etc. “oata | [* are | [© trans | |_mive | | sum ° cau | [sure | | Mooiey suoce_| |_teme. | | “iuoce = area | "tear | |" ne. NO. NO. veRse "temp. oruers | | “aby © TYPES OFTRAP tuenmo | | sucker | | viseTM2 Manual (M) (2:2)012492 (10) Battery Pack Cover - Cover for 6V/600MAH Battery Pack. —=-— a Can be removed and installed by operator (11) Interface connector - Connects the interface cable for data © @ transfer. (12) AC adaptor/charger jack ma cl = Connects the AC adaptor/charger for [J charging or data transfer. i (13) Rear cover am ull ob) ~ Remove this cover during recharging | |=|_ and data transfer. Battery Pack Cover 2 —=—J ch Interface connector —__ | @|] ; , 1° Lo AC adaptoricharger jack Ton Rear cover — } (14) Coiled cable a -- Extends up to six feet, end to end. (15) LED -- Flashes for 15 seconds during measurement and turns off when the measurement ends. Coiled cable LED (16) Probe ~ Contains the hardware used in detecting ultrasonic frequency Probe and surface temperature. Serial numberTM2 Manual (M) (2.2)012492 Function Keys Operation (1) DATA TRANS key To transfer the steam trap test data between the internal memory of TM2 and your personal computer. (2) DATETIME key a) To confirm and correct the date and time immediately after the power is turned on b) Displays the date and time (year, month, day, hour) of test for each trap after the completion of the test procedure. (3) SUM key When used in conjunction with the numeric keys, this key displays the number of inspected traps, number of malfunctioning traps, malfunction rate, and details of faulty traps. (4) CALLJUDGE key Displays the evaluation results for each trap following the completion of the test procedure. (5) SURFC. TEMP. key Displays the surface temperature for each trap following the completion of the test procedure. (6) MODIFY JUDGE key To manually adjust the evaluation results obtained from automatic evaluation (7) AREA NO. key Allows the input of a user-specified area number (3 digit number), to easily identify and group steam traps by general location within a facility. (8) TRAP NO. key Allows the input of a user-specified trap number (5 digit number), to separately identify each trap. (9) REVERSE key a) Reverses the sequencing of displayed data for the DATE TIME, CALL JUDGE, SURFC. TEMP, MODIFY JUDGE and SUM function keys. (This key has no effect on the AREA NO. and TRAP NO. keys.) b) During trap model entry, reverses the sequencing of registered trap models using the Trap Types keys (Float, Disc, Bucket, etc.). (10) SHIFT key a) To enter alphabetic characters for the area number and trap number. b) To confirm the pressure (only for thermostatic steam traps) and temperature (only for temperature adjustment traps). (11) ENT key To enter information on the LCD display into the internal memory of TM2.TM2 Manual (M) (2.2)012492 TM2 Procedural Flow Chart The diagram below illustrates the basic operating procedure. Proceed in sequence by answering either YES or NO to the questions. Connect probe Y ‘Turn on power switch ¥ YES Data transmission necessary? Transmit data Reset date/time Enter area no. YES. } eo 3 Enter trap no, t Enter model no. t Measurement Enter pressure Enter pressure Select condensate Enter set temperature load range (Thermostatic, Float, Disc, (Temp. Adjustable traps) Bucket, Other traps) Evaluation Yes modification necessary? Modify evaluation YES Turn off power switchTM2 Manual (M) (2'2)012492 Start of Operation Charge the unit for approximately six hours before use. Following this, check for sufficient charge, and then begin use. 1. Connecting the Probe The coiled cable is used to connect the probe to the main unit. Attach the screw connectors. 2. Turning on Power 1. The display when internal memory Press the ON key. contains measurement data that has not been transferred to the personal The display will show one of | omputer. two messages: (1) "Not transmitted. if OK, press DATE TIME key” When the internal memory contains measurement data which has not been transferred to a personal computer. (2) “Trap No. 000-00000" on UGHT OFF When the internal memory has been cleared, or data has been transferred. NOT TRANSMITTED IF OK, PRESS DATE TLV Trap Man TM2 2. The display when internal memory has been cleared or transmit processing performed The previous data will be deleted when new data is input for the same trap number, or another [SEE Gi measurement is taken. If the MODEL previous data is needed, it must be transferred to the personal computer for storage before using TM2. TLV Trap Man TM2 ox] [user] [oF Note Even when the data is transferred to a personal computer, it will also remain inside the TM2 until memory is cleared.TM2 Manual (M) (2.2)012492 3. Clearing the Internal Memory There may be meaningless data (test data, etc.) in the internal memory of TM2 when the unit is new or when the battery or ROM is changed. in this case, follow the procedure below to clear the internal memory Note Clearing the internal memory after data has been input will delete all data, however any registered trap models that have been input will remain in memory. Clearing Procedure: ® Press the SUM, 9, and 9 keys in this XKCLEAR DATA, OK order. PLEASE CONFIRM The data is not yet deleted at this stage. If you wish to cancel the TLV Trap Man TM2 deletion procedure, turn off the power. Giz: @ Press the ENT key. After a few seconds, the message “Clear completed” will be displayed. This clears the data in the internal memory. TLV Trap Man TM2 CLEAR COMPLETED Notes * The memory can be cleared at any time regardless of the state of the display. * Itis not possible to clear only a portion of the memory * When clearing of certain trap nos. or models is desired, it is possible to use the PS1 software on the personal computer to modify or delete the data, and then to send the remaining data to the TM2 using the data transfer functions. (Refer to the PS1 Software User's Guide)TM2 Manual (M) (2.2)012492 4, Setting the Internal Clock Press the DATE TIME key. As an example, press the following DATE: Y/M/D H:M keys to set the date and time to 87/11/20 14:25 1987, Nov. 20, 14:25 hours: TLV Trap Man TM2 8711201425ENT ON LGHT OFF If a mistake is made, start again from the beginning. Notes This mode is available only immediately after the power is turned on. If this key is pressed during measurement, the previous measurement date/time corresponding to the indicated trap number is displayed. @ The internal clock operates continuously 24 hours a day, whether the unitis on or off.TM2 Manual (M) (2:2)012492 5. Entering the Area number and Trap number Press the AREA NO. key. Enter the area number as three alphanumeric characters. To enter numbers, press the numeric keys. To enter letters, first press the SHIFT key. After confirming that “S" is displayed after “NO.” on the display, press an alphabetic character input key. Alphabetic characters are labelled in sequence (from A to 2) in the upper left corner of each key. “Sis displayed when the SHIFT key is pressed and disappears when the SHIFT key is pressed auain, Example: entering "A01” as the area number, Press AREA NO. and SHIFT (Make sure that “S" is indicated.) Press A and SHIFT. (Make sure that the “S" indication disappears.) Press0 1 and ENT If an entry error is made, enter the proper characters again from the beginning. Press the TRAP NO. key. Enter the trap number as five alphanumeric characters. The entry procedure is the same as for the area number. $000-00000 MODEL No. TLV Trap Man TM2 on uGHT OFF NO. A01-00000 MODEL TLV Trap Man TM2 ON uGHT OFF NO. A01-00001 MODEL Example: entering “00001" as the [trap number. Press TRAP NO. 00001 ENT If an entry error is made, enter the proper characters again from the beginning. TLV _Trap Man TM2 uGHT OFF on | ~10-TM2 Manual (M) (2.2)012492 6. Selecting the Model Certain information such as trap models can be entered directly into the TM2 memory using the keypad, if it has not already been automatically transferred to TM2 memory from a personal computer. Press one of the six trap type keys : FLOAT, BUCKET, DISC, TEMP ADJ, THERMO, or OTHER to select the trap type. NO. A01-00001 MODEL (0) DISC TLV Trap Man TM2 oN UGHT OFF For example, when the DISC key is pressed, “(0) DISC” will be displayed There are two methods for entering the trap model: a) Using the model code book Select the model name by referring to the model code book, entering the four digit number, and pressing the ENT key. For example, press 00 0 4 to input “TLV-A3N". NO. A01-00001 MODEL (0) 0004 TLV Trap Man TM2 oN UGHT OFF NO. AQ1-00001 MODEL (0) A3-N The model name “A3-N’ is entered when the ENT key is pressed. TLV Trap Man TM2 oN UGHT OFF -11-TM2 Manual (M) (2.2)012492 b) Using reaistered model names Up to nine different model names can be “registered”, or stored, in NO. A01-00001 TIM2 memory for each trap type, MODEL (1) _A3-N The model names are displayed in TLV _Trap Man TM2 order each time the corresponding " on | fucut] | ore trap type key is pressed. For example, when “A3-N” is registered as the first DISC trap, the display is as shown on the right. Notes © Although the model name is displayed, it has not yet been entered into TM2 memory. The model name is entered by either of the following methods: (1) Conducting a trap measurement (Refer to p.20) (2) Pressing the probe tip against a hard surface, such as a desktop, for approx. one second (Refer to p.15). © Ifthe specific trap model is not found, judgement by entering the trap classification (ie., (0) Float, (0) Disc, etc.) is still possible. Accuracy of the test results may decrease because the judgment criteria may differ for each trap type even though the classification is the same. -12—‘TM2 Manual (M) (2:2)012492 Fundamentals of Measurement 4. Principle of judging steam leakage. a. Basic data for TM2 judgement are the results of multiple tests taken by “Automatic steam leakage test apparatus.” b. Analysis is made of the correlation between the rate of steam leakage and ultrasonic waves generated by each type of trap. Standard measuring point 1200 traps Detect the ultrasonic at the filed standard measuring point at the trap inlet. ———> steam loss For each trap a correlation exists between the rate of steam leakage and ultrasonic waves generated by the trap at each level of steam leakage failure. As shown in the figure above, ultrasonic wave data for 1200 traps was analyzed from a common standard point; a flat surface filed on the top of each trap inlet. c. The correlation between ultrasonic waves and steam leakage mentioned above is stored in the ROM of the TM2 making on-site judgement of leaking traps possible. Display in TM2 Blowing 15] Large 14] leakage 13] 12| "1 10) 9 Medium 8 leakage 7 6 5 Small 4 leakage 3 2 1 Good 0 ————> Ultrasonic -13—TM2 Manual (M) (2:2)012492 2. Principle for LOW TEMP Judgement If no condensate is held up at the inlet side of the steam trap, the temperature of the trap inlet will be equal to the saturation temperature for the steam pressure at the same location. However, if condensate is held up at the trap inlet due to trap blockage, inadequate discharge capacity or low temperature setting of temperature modulating traps, ultrasonic waves will disappear and the temperature at trap inlet will decrease. The extent of condensate backup and trap blockage can be judged by measuring temperature at the trap inlet. Since the correlation between each steam pressure and saturation temperature are stored in the ROM of the TM2, a comparison of this value with actual measured surface temperature T; at the standard measuring point of the actual trap (the location filed flat at the top of the trap inlet) enables on-site judgment of condensate backup. Display in TM2 T1< 60% of Saturation temperature > (LOW TEMP) The judgment criterion of “less than 60% of saturation temperature” for condensate backup has been selected because our past tests of various trap types , body materials and thicknesses, and environmental conditions show that the trap surface temperature sometimes decreases by up to 40% of saturation temperature even in normal operation. When a LOW TEMP judgment results, no ultrasonic judgement is made. Although we do not recommend it, the factory set LOW TEMP standard of 60% can be changed to any other level. See page 33, Review of Summary Data, for instructions on the procedure to follow. The selection of an alternative LOW TEMP level* may allow the ultrasonic judgement of traps with low surface temperatures to be included in one of the “faulty trap groups”; i.e., allow a judgment of GOOD or LEAK to take precedence over LOW TEMP. * The value of the new level will not be automatically transmitted to the PS1 Software with the survey data. Whenever the standard is changed, please record the new standard; as part of the file name, for instance, ~14—TM2 Manual (M) (2:2)012492 Model Name Input Procedure If the trap numbers and models are transferred to TM2 from the personal computer before going to the site, there is no need to input models on-site. However, in cases where trap models must be entered into TM2 directly during trap inspections, either of the following two methods can be used 1. Individual Entries by Using the Code Book ‘Asan example, the following steps illustrate the procedure for entering float-type J7N-16 as Trap No. 00001 and disc-type A3-N as Trap No. 00002 NO. 001-00001 MODEL @_ Press the ON key to turn on the power. TLV Trap Man TM2 @ Enter the following: AREA NO. +001 ON LIGHT OFF TRAP NO.--00001 ® Call up model J7N-16 by pressing the type key to be input (FLOAT key in this case) until J7N-16 appears on the display. If J7N-16 is NO. 001-00001 not found among registered MODEL (1) _J7N-16 models (1) to (9), refer to the section on Registration of Models (page 17). @® Press the tip of the probe (sensor) against a desktop, etc., and hold for approximately 1 second. TLV Trap Man TM2 ON UGHT OFF Note If there is already measurement data for the input trap number, performing the operation above will erase this measurement data. -15—® Although “CHECK/ERROR” is displayed on the screen, this is not a problem. Here, “J7N-16" is input for Trap number 00001. The evaluation is “not inspected” at this time. © Pressing the TRAP NO. key again will indicate the entered model for confirmation. @ The next trap number is displayed when the TRAP NO. key is pressed again. Confirm that the trap number is 00002 and press the next trap type key (DISC in this case) to display “A3-N", Steps 4 to 7 can be repeated to enter model nos, (evaluation: not. inspected) for each trap number. Notes @ Ifan incorrect model name is entered, it can be corrected by re- entering the proper model © Ifamodel name is entered for a trap number, the model number can be corrected but the trap number cannot be deleted. © The type name for TM2 can also be entered by creating alistona Personal computer and transferring it to the TM2. ‘TM2 Manual (M) (2:2)012492 NO. 001-00001 ## CHECK/ERROR ## TLV Trap Man TM2 ON uGHT OFF ———— NO. 001-00001 MODEL _J7N-16 TLV Trap Man TM2 ——————————— —— NO. 00171-00002 MODEL (1) A3-N —————— TLV Trap Man TM2 oN uGHT OFF -16—TM2 Manual (M) (2:2)012492 Registration of Models Although steam trap model names can be entered into TM2 individually by code input using the supplied code book, this method can be tedious and time-consuming if the code book is used each time a trap model is entered. This is especially true if there are several trap applications throughout the facility which have the same trap model installed. Amore convenient method of trap model entry is available through the use of trap model registration. Each different type of trap is represented by one of six keys in the center of the TM2 keypad. For each of these keys, up to nine specific trap models can be “registered” (i.e., stored in memory), as illustrated below: + Trap Type keys, —————__—____> DISC || BUCKET |] THermo |) FLOAT || TEMP. || OTHERS A ~ (0) Disc BUCKET THERMO = FLOAT —TEMP.ADJ, OTHERS. a) (2) (3) (4) B (5) (6) ”) (8) (9) A. Generic model names, used for input when the actual model number is unknown or is not listed in code book. B. Nine specific trap models can be registered for each trap type in the TM2 memory by using the four-digit code numbers from the code book. The registered model names can be input by displaying them in sequence each time the various type keys are pressed. For example, register J7N-16 to Float (1). NO. 000-00000 MODEL © Press the ON key. TLV Trap Man TM2 on uGHT OFF @ Press the TRAP NO. key. -17—Press the type key representing the trap type to be registered For the float type, press the FLOAT key. The generic float model “(0) float” will be displayed. Press the FLOAT key again. A different model name, such as J3N- 16, may already be registered in (1) when the unitis first used. Enter the code (four digits) to be registered using the numeric keys. Obtain code number 1219 from the code book for J7N-16, and enter. Press the ENT key after confirming the code. In this example, J7N-16 was registered as the first float type. ~18- TM2 Manual (M) (2:2)012492 —— NO. 000-00000 MODEL (0) FLOAT TLV Trap Man TM2 oN UGHT OFF NO. 000-00000 MODEL (1) J3N-16 Sa oéoM TLV Trap Man TM2 ON uGHT OFF (SS _) NO. 000-00000 MODEL (1) 1219 St TLV_Trap Man TM2 SS on UGHT OFF NO. 000-00000 MODEL (1) _J7N-16 TLV Trap Man TM2 on UGHT OFFTM2 Manual (M) (2.2)012492 @ The second model can be registered by pressing the FLOAT key again. NO. 000-00000 MODEL (2) Up to 9 models of each trap type can be registered in the same manner. TLV Trap Man TM2 oN UGHT OFF Notes Registration of trap models in (0) is not possible. Inputis not possible if the code does not match the type. (e.g., the code number for a disc trap cannot be entered if the FLOAT key was pressed.) If registration is made to a location where a model is already registered, the previously registered model is deleted. © Press the REVERSE key to go back to a previous model name. OVERVIEW OF MODEL REGISTRATION ROM Approxi- mately 1,000 trap Temperature model adjustable names are FORaNIS sweamzete..| Inputthe | stored. UFO3FB8, ete, sort ot, correspond- total of 3 ing code number from code book ~19-—TM2 Manual (M) (2.2)012492 Trap Measurement 1. Verifying TM2 Display Information Check the display before beginning measurement. (1) (2) (3) (4) (5) Have the year, date and time been set? Have the area number and trap number been entered? Has the applicability of the LOW TEMP standard been confirmed? (see page 14) Is the model number displayed? Does the displayed model number match that of the trap to be measured? 2. Trap Measurement Using the Probe Measurement is made by holding the probe perpendicular to the top of the trap inlet @ and depressing the sensor tip for 15 seconds. Care should be taken not to strike the probe tip against the trap and to hold it firmly to make sure it does not slip. NOTE Wait at least 30 seconds after turning on the power before beginning measurement. (Data may change if a measurement is made within 30 seconds after the power is turned on.) —20-TM2 Manual (M) (2.2)012492 Ifthe measurement cannot be made at the standard measuring point due to the trap shape or installation at a nearly inaccessible location, a flat surface can be prepared on the side © or the bottom of the trap inlet. If none of the above is possible due to insulation, etc., the pipe © at the trap inlet or the trap body © can be substituted. However, the more distant the measuring point, the less sensitive; and the judgment of the rate of leakage is less than the actual, when leakage occurs. On the other hand, however, near the trap center, the rate of leakage judged will be greater than the actual. (There is almost no influence on the judgment if the trap is normal.) Judgment is not possible at either the trap outlet © or the outlet piping ©. Ameasurement takes approximately 15 seconds. The LED on the back of the probe ess esaan flashes during measurement, Temp 123°C 15 and the surface temperature, "TEMP. °C", is displayed. TLV Trap Man TM2 After 15 seconds, the LED turns = offand a beep sounds, indicating the end of measurement. Counts down from 15 to 01. Displays the time remaining until measurement ends. ~21-. Proper Method of Holding the Probe Proper inspection is not possible unless the tip is pressed firmly and is perpendicular with the inlet pipe or trap body. The flatter and smoother the measurement surface of the steam trapis, the more accurate the measurement will be. Dust, dirt and uneven paint surfaces prevent the detection of ultrasonic waves. For such surfaces, smooth with a flat file, ‘When pressing the probe against the trap, press the tip directly against the trap itself and make sure itis perpendicular to the surface. Do not move the probe tip during measurement. Push down on the probe until the tip of the probe comes into contact with the trap surface. Use only the force of your arm Using your body weight or a lever will vary the measurement values. ‘TM2 Manual (M) (2:2)012492 Approx. 16mm, —22—TM2 Manual (M) (2.2)012492 4, Automatic Evaluation "PRESS.? xxx KG" is displayed after measurement ends: NO. A01-00001 This asks for the inlet pressure (gauge PRESS.2 000 KG pressure) of the measured steam trap. "xxx KG" represents the saturated TLV_Trap Man TM2 steam pressure based on the measured surface temperature. on LIGHT OFF Confirming or modifying the input pressure If the inlet pressure of the measured steam trap is known, input the NO. AQi1-00001 pressure using the numeric keys (e.g., PRESS.? 5.5 KG 055 for 5.5 kg/cm?) and press the ENT key. (There is no need to input the TLV Trap ManTM2 decimal point since it is fixed.) Input the steam trap inlet pressure (immediately before the trap) as precisely as possible. It is possible that the pressure immediately before the trap is substantially lower than the inlet pressure of the steam using equipment. For instance, itis apparent that the pressure immediately before the trap will be much less than the equipment inlet pressure when a control valve activated by temperature is used at the equipment inlet. ON LGHT OFF Although the best way to find the exact pressure is to install a pressure gauge immediately before the trap, judgment can be made as follows if this is not possible: TM2 displays the steam pressure correlated to the actual measured surface temperature. If the steam pressure is unknown and cannot be more accurately estimated, pressing the [ENT] key will result in automatic judgment using the displayed steam pressure as the actual. Accuracy may be reduced as the surface temperature may differ from the actual internal temperature of the trap. ~23-When the steam trap is other than a temperature adjustable type If the automatic evaluation result cannot be clearly determined by TM2 after the 15 second measurement, the unit will ask if the condensate load at the trap isin the minimum, moderate, or maximum range in relationship to the trap’s capacity. Select one of the following choices: 1("7") When the condensate load is unknown, or is within the moderate range (10% to 90% of trap capacity). 2 ("MIN") When the condensate load is within the minimum range (less than 10% of trap capacity). 3 (“MAX") When the condensate load is within the maximum range (greater than 90% of trap capacity). Based on knowledge or estimation of the actual condensate load, press either 1, 2, or 3. The evaluation result will be displayed. Press the SHIFT key while the evaluation results are displayed (screen on right). The input pressure is displayed once again, At this point, the pressure can be corrected and re- entered, if necessary. The SHIFT key can be used for correction only after the evaluation results displayed TM2 Manual (M) (2.2)012492 NO. A01-00001 MODEL _J7N-16 TLV Trap Man TM2 oN LIGHT OFF When the evaluation result cannot be determined immediately after trap measurement. CONDENSATE LOAD? 1:2 2:MIN 3: MAX TLV Trap Man TM2 ON UGHT OFF When the evaluation result is *"Go0D" —— NO. A01-00001 JUDGE GOOD TLV Trap Man TM2 oN LIGHT OFF ~24— 2TM2 Manual (M) (2.2)012492 When the steam trap is the temperature adjustable type The unit asks for the set temperature of the measured temperature adjustmenttrap. NO. A01-00001 If the temperature has not been SET TEMP.? 070 °C entered previously, “70°C” will be displayed. If the temperature is known, enter it pressing the numeric keys 0,9 and 0 (if the temperature is 90°C for example) and press the ENT key. TLV Trap Man TM2 on OFF When the evaluation result is “FAIL ADs" If the temperature is unknown, press the ENT key while "070°C" is displayed. The set temperature can be confirmed or modified in the same manner as for THERMO (thermostatic type) by pressing the SHIFT key while evaluation results are displayed. NO. AQ1-00001 JUDGE FAIL ADJ TLV Trap Man TM2 oN uGHT OFF Evaluation Standards: For traps other than Temperature Adjustable © Evaluated as blocked when steam trap surface temperature is less than 40°C. Evaluated as LOW TEMP when steam trap surface temperature is less than 60% of saturated temperature. (see page 14, Principle of LOW TEMP Judgment and page 33, Review of Summary Data) For Temperature Adjustable traps © Evaluated as adjustment failure when steam trap surface temperature isnot within +20% or ~ 30% of set temperature. ~25—Note If the probe tip comes away from the steam trap during the 15 second measurement, the display at right will appear. To re-test, simply press the probe tip against the trap inlet surface again. TM2 Manual (M) (2:2)012492 NO. A01-00001 ## CHECK/ERROR ## TLV Trap Man TM2 ON UGHT OFF After measurement, one of the following eight automatic evaluations will be displayed: Evaluation Basis BLOWING Steam leakage levels above 15 LEAKIL Steam leakage levels 10 to 15 LEAK/M Steam leakage levels 5 to 10 LEAKIS Steam leakage levels 1 to 5 LOW TEMP Surface temperatures below 60% of saturation* BLOCKED Surface temperatures below 40°C FAIL ADJ Surface temperatures more than 20% above or 30% below set temperature coop Normally operating Leak Level : The evaluated leak level, or the measured amount of leakage from the steam trap, depends on the following factors: (1) Changes in the amount of condensate load (2) Constant changes due to pressure fluctuations at the inlet side of the trap (3) Presence/absence of other steam flow noise (operation of reducing valves, etc.) (4) Condition of trap inlet surface to be measured (flatness, smoothness, rust, paint, etc...) (5) Measurement position (6) Manner in which probe is held against surface Thus, evaluation will vary slightly with each measurement. *(see page 14, Principle of LOW TEMP Judgment and page 33, Review of Summary Data) =26—TM2 Manual (M) (2:2)012492 Surface Temperature: The trap surface temperature varies according to the following, even for traps at the same steam pressure. (1) Condition of the trap surface to be measured (flatness, smoothness, rust, paint, ete. (2) Difference in holding the probe. In particular, the displayed temperature value is low if the probe is tilted. (3) Composition and thickness of the trap body. (4) External environment (ambient temperature, wind speed, wind direction, etc.) Steam traps which cannot be evaluated Although approximately 1,000 models of traps listed in the code book can be tested, the TM2 cannot evaluate traps in the following cases: 1)Steam traps which are affected by high velocity steam flow noise Examples: * Trap for TLV-COSPECT(PRV with built-in separator and steam trap) * Trap for TLV-DC3 (cyclone separator and steam trap) * Drip leg applications at pressure reducing stations and turbines 2)Steam traps for very high pressures (greater than 40 kg/cm?) and temperatures (greater than 255°C) Examples: * Drip leg applications on high pressure boiler steam mains High temperature heat exchangers and reactor vessels (When steam traps at temperatures higher than 255°C are to be inspected, use the UC-1 Ultrasonic Audio-visual Checker and manually input the results by selecting the Log Maintenance Menu after the PS1 Trap Management Log file has been established. UC-1 results of GOOD, BLOCKED, LEAK BODY, and LEAK GASKET can be entered. For UC-1 readings of 0-2, use LEAK S, level 3; for 3-4, use LEAK M, level 8; for 5-6, use LEAK L, level 13; and for 7-10, use BLOWING, level 15.) 3) High capacity steam traps having a condensate discharge of more than 3,300 kg/hour Examples: * Large process equipment (heat exchangers, tank coils, etc.) 4)Steam traps which are used at approximately 0.5 kg/cm? or below. Due to low ultrasonic wave frequencies of low velocity leaking steam =27-TM2 Manual (M) (2.2)012492 5. Judgment Procedure ® and @ The diagram below illustrates the basic judgment procedure ©. Proceed in sequence by answering either YES or NO to the questions. No Datertime OK? Reset date/time YES YES Enter area no, NO ee 2 Enter trap no. re ¥——— trap models Enter trap type pave already ‘Apply probe to the standard Measurement measteng joint of the trap to be 1 diagnosed (or 15 seconds) Enter steam pressure immediately ahead oftrap Surface temperature less than 40°C? Surface temperature less than 60% Sat.°C?* Measurement of face temperature cosas eeMestumncouy psa ores towtemp | reat | | | i | Select condensate Btockeo | arene a No feam leakage noise? (ultrasonic) measuremen i “NORMAL” i eee j= cemeertunpenemy | i | dosmaltif | “bLarge} | “Blowing” | leakage” | leakage" leakage” |) | over | Level 1-5 []_ Level 6-10 Level 11-15 | | Level 15, / . : i *(see page 14, Principle of LOW TEMP Judgment and page 33, Review of Summary Data) =28—Judgment procedure @ ‘Judged BLOCKED or LOW TEMP Is the measured object steam trap? No Bid more than 30 minutes elapse after steam was supplied? No ‘Was the probe applied to the inlet side ofthe steam trap? No ‘Was the tip of the probe applied perpendicularly tothe trap? Were rust and paint on the trap autface removed end a fiat surface pared with a file? fully opened? Was the correct inlet pressure input? No ‘Was the correct condensate rate input? Trapian can be used only for steam traps, Within 30 minutes, exact judgment is not possible due to large load changes. The TM2 probe Is designed to be aPplied tothe inlet side. Precise surface temperature measurement of the tap is not possible If it is not fully opened, surface tamporature of the trap decreases as condensate isobstructed, Bxact judgment is not possible [because operation judgment is made after comparison of the surace temperature with the saturated temporature automatically calculated from the input pressure 1e2.Min" large discharge of condensate, accuracy of judgment will be affected. Is selected in spite of a Batch operation Sok. a ae) isthe control valve opening constant? No. ‘Was the correctinlet pressure input? Continuous operation >C Nocontrol Proportional control valve Gan the operator contirm the existence of slowstart-up or any uneven heating? Good |*—-(C Confirm bystethoscope _)-* [Inadequate = | especty == ~29-TM2 Manual (M) (2:2)012492 When Modification of the Evaluation Result is Required Since in all cases the automatic evaluation standards are used, the automatic evaluation result should be modified by the inspector as necessary after trap measurement. Evaluation results can be modified using the MODIFY JUDGE key. Example: Change the automatic evaluation result BLOCKED to NOT { >) INS. NO. A01-00001 Press the MODIFY JUDGE key once. JUDGE BLOCKED Sass TLV Trap Man TM2 oN UGHT OFF The NOTIN SVC indication appears. (———_—_—_—______—~ The evaluation is altered the NO. A01-00001 instant it is modified. JUDGE NOT IN S TLV Trap Man TM2 ON UGHT OFF When BLANK is selected, the data ((¢———— item will not be counted in the NO. A01-00001 total. JUDGE TLV_Trap Man TM2 ‘ON UGHT OFF -30-M2 Manual (M) (2:2)012492 The following evaluations can be input using the MODIFY JUDGE key. 1 BLOWING Blowing, or failed open 2 LEAKIL Large steam leakage 3 LEAKIM Medium steam leakage 4 BLOCKED Blocked, or failed closed 5 NOTINS Notin service 6 LowTEM Low temperature* 7 LEAKS ‘Small steam leakage 8 GOOD Good, or normally operating 9 FAILED ADJ Failed set temperature adjustment 10 UGASKET Steam leak from trap gasket 11 UBODY Steam leak from trap body 12 NOT CHECK Not checked (i.¢., not measured) 13 --— (Left blank, for situations in which the trap condition is other than those listed above. BLANK is not counted in the total) Nes: APA ‘© When an evaluation result is modified by pressing MODIFY JUDGE key, the date and time of measurement are modified to the date and time the MODIFY JUDGE key is pressed. © When LEAK/LARGE, LEAK/MEDIUM, or LEAK/SMALL evaluation result is modified, the numeric level of leakage is not indicated. Consecutive Measurements Trap numbers can be input sequentially when there is no change in the area number. During steam trap inspection, if the TRAP NO. key is pressed repeatedly, the trap numbers will be presented one by one, making this convenient for ‘testing steam traps in numerical order. If the next area is desired, press the AREA NO. key, input the area number, then press the TRAP NO. key for trap number input. *(see page 14, Principle of LOW TEMP Judgment and page 33, Review of Summary Data) ~31—Review of Summary Data TM2 Manual (M) (2:2)012492 The following TM2 summary data processing is possible by pressing the SUM key together with the numeric input keys. Notte § A When the SUM key is used for summary data processing, measurement of traps is not possible. To return to the inspection mode, press the SUM key followed by the 0 key. The total number of data items, number of trap failures, and trap failure rate are indicated when the SUM key and then the 1 key are pressed.* Number of data items —— TOTAL Q'TY 0123 FAIL. 0012 009.8% Example: Number of data items Number of failures 12 Failure rate 9.8% *Does not include data items for which the judgment is modified to BLANK. 123" Press the SUM key followed by the 2 key to display details on the inspected traps which were determined to be malfunctioning. The failed trap evaluation is displayed. Pressing the CALL JUDGE key will display details on the next malfunctioning trap. TLV Trap Man|tm2 i ( on jumber of failures UGHT [ OFF Zz Failure rate NO. 001-00003 JUDGE LEAK/S 02 TLV Trap Man TM2 (Cod feel Tel) NO. 001-00012 JUDGE BLOWING TLV Trap Man TM2 (ie =I) UGHT ~32—TM2 Manual (M) (2:2)012492 Pressing the keys SUM 4 will display the LOW TEMP factor. The judgment standard is factory set at 60% of saturated temperature. When a LOW UTEMP, FACTOR 60% —_OFSAT. TEMP. TEMP judgment is displayed, no other judgment will be made. Whenever ultrasonic analysis is desirable in spite of low temperature or when the preset level is too low; the percentage can be on | [uicHT| | orF revised to any other level between 00 and 99. TLV Trap Man TM2 Example: When UTEMP. FACTOR is displayed after pressing SUM 4, the percentage can be changed from 60% to 30% by UTEMP. FACTOR pressing [3], [0], [ENT]. 30% OF SAT. TEMP. Once changed, all subsequent TM2 judgments will be based on the new value. The new setting will be maintained as on ugHT| | OFF long as the memory back-up battery has enough voltage. In the event of battery failure, the setting should be confirmed following main battery replacement and revised if necessary. TLV Trap Man TM2 Pressing the SURFC TEMP key will NO. 001-00003 display the surface temperature of the Te / SURF. 143 °C indicated trap number. TLV Trap Man TM2 on uGHT OFF a © Malfunctioning trap information is displayed in the order of area and trap number each time the CALL JUDGE key is pressed. This also applies to the SURFC TEMP and DATE TIME keys. © Display in reverse order is possible by pressing the REVERSE key. ~33—TM2 Manual (M) (2/2)012492 Pressing the DATE TIME key will display the date and time of measurement (yeat/month/day and hour) for the displayed trap number. TLV_Trap Man TM2 NO. 001-00003 CHECK 87/11/28 15 (Example: 1987, November 28, 15:00) on uGHT OFF The number of TM2 measurements is automatically stored in the memory, and itis possible to confirm this CHECK COUNT number by key operation. 000002 Pressing the keys SUM 7 7 will give TLV_Trap Man TM2 the total no. of TM2 measurements that have been taken since the unit on | fucut] [ore was new of recalibrated. If the SUM and the SHIFT keys are pressed, the battery charge condition will be displayed as a bar chart. The sketch below roughly shows the relationship between the bar chart and remaining usable time. (When back light is not used). BATTERY CHECK EQ0OODOO00000000F [ Lote torsoues "8" displayed (Usable for about 1 hr) “Battery voltage low!" display fixed and TM2 unit is automatically OFF. Notes © Pressing the keys indicates only the charge condition immediately after pressing the keys * Battery charge conditon can be displayed at any time -34—TM2 Manual (M) (2:2)012492 Data Transfer Pressing the DATA TRANS key followed by the 1 or 2 key allows data to be transmitted to or received from a connected terminal such as a personal computer. (Personal computer software is required to transmit and receive data.) Refer to the PS1 Software User's Guide for details on the data transfer procedure. The data transfer operation should be performed with the AC adaptor connected. (Be sure to use a power outlet free of noise and surges, such as that used by personal computer, etc.). DATA TRANS 1 Transfer the memory data of the TM2 unit to a personal computer. ##DATA TRANSMIT## #ON TRANSMIT# The displayed message indicates that transmission isin progress. TLV Trap Man TM2 on UGHT OFF DATA TRANS 2 This prepares the TM2 so that it can receive data through the connected interface cable. The READY TO RECEIVE displayed message indicates that the unitis ready for reception. TLV Trap Man TM2 To cancel the reception ready state, turn off the power (press OFF key). oN UGHT OFF Notes © Other operations such as measurement and review of summary data, etc., are not possible during data transfer. © The data within the TM2 is retained within the unit even after it has been transferred. It must be intentionally cleared. -35-—Display of Error Messages 1. Low Battery Voltage Immediately after the power is turned on, the display at right appears when the battery voltage is below the rated level During normal use, a low battery charge is indicated by a “B” to the left of the area number. When there is a further drop in voltage, the display on the right remains constant, and further operation stops. Following this, TM2 will automatically shut off to conserve power. Notes When any of the messages above is displayed, recharge the unit as soon as possible. [Refer to the charging procedure (page 39) when recharging the unit.] Operation is still possible for approximately 1 hour after the low battery level message’is first indicated (when the back light is not used) SSS TM2 Manual (M) (2:2)012492 —— BATTERY LOW/VOLT #PLEASE CHARGE# TLV Trap Man TM2 [on UuGHT OFF Bis displayed EecJES]S— NO. B001-00001 MODEL _A3-N ext to “No.” TLV Trap Man TM2 BATTERY LOW/VOLT #PLEASE CHARGE# TLV Trap Man TM2 OFF [ox [ber —36—TM2 Manual (M) (2.2)012492 Measurement Error If measurement is started without entering the model number, . NO. 001-00001 measurement is interrupted and ## CHECK/ERROR ## the following message is displayed: TLV Trap Man TM2 ## CHECK/ERROR ## ON UGHT OFF If this occurs, press the TRAP NO. key once to clear the error, and enter the model number before beginning measurement. The same indication appears if the probe is lifted away from the (7 steam trap during measurement. NO. 001-00001 If this occurs, simply press the i CHECK/ERROR ## probe against the steam trap to begin measurement again. TLV Trap Man TM2 ON uGHT OFF Data Transfer Error If an error occurs during data transfer, the indication on the ##CHECK/ERROR#H# right is displayed, and the transfer DX TRANSMIT/ERROR% operation is stopped. As the most common cause of this TLV Trap Man TM2 error is a mistake in the data transfer procedure, refer to the data transfer section in the PS1 Software User's Guide for the correct procedure ON uGHT OFF 37Malfunction Diagnosis TM2 Manual (M) (2:2)012492 Check the following items when this unit does not perform as described. Contact your nearest sales office informing them of the malfunction status if ‘the prescribed operation does not work after checking the following items. Symptom — Confirmation Items No display indicated, or unit immediately shuts off jautomatically when ON key is pressed Isthe unit charged? © Has the AC adaptor/charger become disconnected from the outlet? ® Isthere voltage from the AC adaptor/charger? Measurement not possible, jor a measurement error Joccurs © Is the coiled cable loose? @ Has the model name been entered? © Has the probe tip been applied to the trap for 15 seconds? © Has the sum mode been selected? (Return to measurement mode by pressing SUM 0) |AREA NO., TRAP NO., etc., keys do not work © Has the sum mode been selected? (Return to measurement mode by Pressing SUM 0) Probe tip does not pop back lout when depressed © Is there any foreign material on the probe tip? Data transfer to/from personal computer not possible | © Isthe interface cable properly attached? Has the data receive mode been selected? (Press DATA TRANS 2) ¢ Donot attempt to disassemble or repair the unit as precision components could be damaged. —38—TM2 Manual (M) (2.2)012492 Charging Procedure 1. Open the TM2 jacket to reveal the rear cover. 2. Remove the rear cover. 3. Insert the AC adaptor/charger plug into the AC adaptor/charger jack on the TM2 unit. -39-TM2 Manual (M) (2.2)012492 4. Plug the AC adaptor/charger into a wall outlet Notes © Be sure to use only the supplied AC adaptor/charger. @ Use a 120V AC 50/60 Hz power source. © Turn off the power switch of the TM2 unit while charging. * Approximately 6 hours are needed for recharging. Avoid charging for an extended period of time (24 hours or more) as this shortens battery life, Make sure that the ambient temperature is between 10°C to 45°C while recharging © The main TM2 unit will become warm during recharging. This does not indicate a malfunction, unless the unit has been overcharged over an extended period of time. —40—TM2 Manual (M) (2.2)012492 Replacement of Battery Pack Although the battery can be recharged more than 500 times, if it is approaching the end of its life or has been over-recharged, usable hours per recharge will be reduced. In this case, replacing the battery pack with a new one can restore the normal conditions of the unit. Please specify “TLV-TM2-BATTERY PACK" To remove the battery pack, loosen the screw at the side of the TM2 body (4 or 5 turns) and pull the pack from its slot; away from the screw. To install a new pack, reverse the order of the above instructions. Be sure to to re-tighten the screw. (The battery pack removed should not be rebuilt, thrown into a fire or short-circuited). —41-TM2 Manual (M) (2:2)012492 Use of Protective Carrying Cases 1, The protective carrying cases are used to attach the TM2 unit and probe to the operator's belt to protect the TM2 from being dropped and from impact; to improve the operator's efficiency; and to allow the Operator to perform his tasks safely. 2. Details A. Unit Jacket ~ to enclose the TM2 unit. B. Probe Attachment Case ~ to protect the probe and attach it to the Unit Protective Carrying Case. C. Unit Protective Carrying Case with strap. ~ to protect the TM2 unit and secure it to prevent it from being dropped. 3. Carrying Case Procedure. A. Insert the TM2 unit into its Unit Jacket. The transparent side of the jacket goes over the keypad side of the TM2 unit. ‘Transparent Vinyl Unit Jacket Securely close the rear section after inserting the TM2 unit. Attach coiled cable to unit connection Y Attach the strap to the unit by means of the attachment screw. =42—TM2 Manual (M) (2.2)012492 C. Pass the belt through the loops of both the TM2 Unit and Probe Belt Pouches. Probe Belt Pouch Belt provided by user ‘TM2 unit Pouch D. Insert the TM2 unit and probe in their respective pouches. rol The operator passes his hand through the wrist strap before holding the TM2 unit in his hand to prevent the unit from being dropped. Be sure to withdraw your hand from the wrist strap when working near any rotary machine or moving machine parts. —43—Precautions TM2 Manual (M) (2:2)012492 As this unit contains precision components, the following precautions should be taken during use 1 Locations not suitable for TM2 use or storage © Locations subject to extremes in temperature. (i.e., below 0°C or above 40°C) © Locations subject to sudden temperature fluctuations, high humidity, dust, or dirt. © Locations subject to severe vibration, or near motors or transformers. © Inthe rain. @ In atmospheres containing dangerous gases (TM2 is not of explosion proof design or construction), —44—TM2 Manual (M) (2.2)012492 2. Handling of TM2 Unit © Do not subject it to impact. © Do not place objects on top of the TM2. © Do not bring any part other than the probe tip into contact with the high temperature pipes. (especially the rubber probe cover, coiled cable, TM2 protective jacket). © Do not press the keys with a sharp object such asa mechanical pencil. ® Under no circumstances should the TM2 unit or probe be disassembled. Note The protective neoprene tip cover is not heat resistant. Although it will not flash (burn) below 300°C, contact with surfaces above 140°C should be avoided. =45—TM2 Manual (M) (2:2)012492 3. Handling the probe © Do not hit the probe tip against hard objects, or move it while in contact with the trap surface. ‘tt vv set The tip of the probe is the most important part, as its function is to detect ultrasonic frequency and temperature. Since the detection level varies due to factors such as wear or deformation (e.g., dropping the probe or hitting it against a pipe), periodic calibration is recommended. CALIBRATION © Calibration interval: After 30,000 measurements, or when deformation of the probe tip occurs. (Refer to p. 32 of “Review of Summary Data” for determining how many measurements using TM2 have been made.) For recalibration, return the unit, probe and coiled cable in the original case to TLV INTERNATIONAL INC. © Life of the probe tip: Average life expectancy is approximately 80~100 thousand measurements when the trap surface has been properly prepared (filed clean and flat before measurement). Pickug WearingofPickug Degeneration of Thetmersiement Thermo-element Calibration Necessary Wear of the thermo-element depends on how it is handled during measurement. When testing the trap, slowly press the tip against the trap so that the tip does not move or slip. —46—TM2 Manual (M) (2:2)012492 4. Connecting the coiled cable ® The coiled cable attaches to both the TM2 unit and probe || via screw connectors. Be TM2 Manual (M) (2:2)012492 228mm Approx 670g —50—TM2 Manual (M) (2.2)012492 |*———— to1mn ———— = 4. Approx 610g Ie o7anm >) Approx 430g -61-=52— TM2 Manual (M) (2:2)012492TM2 Manual (M) (2.2)012492 Product Warranty 1) Warranty period - one year from delivery 2) Defective parts will be replaced or repaired if a malfunction occurs during this period. 3) The situations below are not covered by warranty: a) (2) (3) (4) Malfunctions caused by the user, such as improper connection, usage, attempted disassembly or maintenance. Malfunctions caused by dirt or rust, etc. Malfunctions due to causes beyond our control, such as natural disasters or other calamities. Accidents or malfunctions not related to the manufacture of the product. —53—