Wireless Steam Trap Monitor User Manual
Contents
1. Wireless Transducer Reader is part of the Cypress Envirosystems Monitoring System This system can be setup one of two ways OPTION A OPTION B Intgration with Plant IT SCADA System Standalone WGR System Cypress Cypress Ld M ry Wireless Wireless XA Es S x TET EE Eye E Field 753 lj Layer L Tal WTR WFM WSTM r a 7 x WSTM WGR WTI _ WGR WTR WFM Figure 4 Cypress Envirosystems Monitoring System Setup Options 3 5 Related Products The WSTM sends data to our Blue Box Server which stores the data in a SQL server The WSTM can communicate directly to the Blue Box Server or through Wireless Range Extenders Cypress Envirosystems Doc 152 10104 01 Rev 1 0 WSTM User Manual Page 8 Wireless Steam Trap Monitor WSTM WSTM je v Blue Box Server BBS Wireless Range Extender WRE Figure 5 Cypress Monitoring System Overview 4 0 Setup 4 1 Components The WSTM comes with the following components f K BL AIAN OO amp amp WSTM Thermocouples External power Sensor input connector connector 4 2 Installation Overview Installation of the WSTM is designed to be non invasive to production operations Mount the unit in close proximity to the steam trap to be monitored Connect the thermocouple clamps on the inlet and outlet of the steam trap Connect the inlet thermocouple to Channel 1 of the WSTM Connect the outlet thermocoupl2. CYPRESS ENVIROSYSTEMS Wireless Steam Trap Monitor User Manual Doc 152 10104 01 Revision 1 0 May 2009 Copyrights Copyright 2008 by Cypress Envirosystems Inc All rights reserved The information in this document is subject to change without notice While reasonable precautions have been taken Cypress Envirosystems assumes no responsibility for any errors that may appear in this document No part of this document may be copied or reproduced in any form or by any means without the prior written consent of Cypress Envirosystems Disclaimer CYPRESS ENVIROSYSTEMS MAKES NO WARRANTY OF ANY KIND EXPRESS OR IMPLIED WITH REGARD TO THIS MATERIAL INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Cypress Envirosystems reserves the right to make changes without further notice to the materials described herein Cypress Envirosystems does not assume any liability arising out of the application or use of any product or information described herein Cypress Envirosystems does not authorize its products for use in mission or safety critical systems or where a malfunction or failure may reasonably be expected to result in significant injury to the user The inclusion of Cypress Envirosystems product in mission or safety critical system applications implies that the manufacturer assumes all risk of such use and in doing so indemnifies Cypress Envirosystems against all charges In no
3. The WSTM has two pre defined channels for data collection and one channel for calculation e Channel 1 monitors the temperature at the inlet of the steam trap e Channel 2 monitors the temperature at the outlet of the steam trap e Channel3 calculates the differential temperature across the steam trap The WSTM inputs are pre configured at the factory and cannot be changed during use 3 3 Sample Collection Samples are collected one of three ways Manual instantaneous reading The user can physically collect a reading at the WSTM Routine data collection A routine sampling interval between 1 and 65000 seconds can be programmed into the WSTM When the WSTM is on this is the default sampling interval that data will be collected Pre programmed short term data collection intervals Each WSTM comes with two pre programmed data collection intervals These are short term intervals of data collection that override the routine data collection rate They are intended to be used for troubleshooting or during known events when the user might want to change the sampling rate for a short period of time See Section 5 0 Operation for detailed instructions for setting sample collection rates The reading value is then transmitted wirelessly as part of the overall Cypress Envirosystems Monitoring System Cypress Envirosystems Doc 152 10104 01 Rev 1 0 WSTM User Manual Page 7 3 4 Cypress Envirosystems Monitoring System The Cypress Envirosystems
4. ate 4 After an additional two seconds all three LED lights will flash 5 Then release the Function button The green LED light will continuously flash To exit from the Configuration mode press the Function button The LED lights will no longer flash 6 0 Care and Maintenance 6 1 Calibration The WSTM is calibrated during installation and initial configuration Routine calibration can be performed and verified by a qualified service technician but is not required See Section 10 0 Support for details 6 2 Battery Life The battery status of the WSTM can be monitored through the web console Battery change out must be performed by a qualified service technician See Section 10 0 Support for details The battery life of the WSTM is dependent on the sampling frequency Typical ranges are listed below Sampling Frequency Estimated Battery Life 1 sample per 1 minute 1 5 years 1 sample per 15 minutes 3 years 1 sample per hour 3 years 1 sample per day 3 years 7 0 Troubleshooting My reading on the web console does not match the transducer display Please verify that the min and max values were set properly on the Cypress Envirosystems Web Console If you have any additional problems please contact us See Section 10 0 Support below for details Cypress Envirosystems Doc 152 10104 01 Rev 1 0 WSTM User Manual Page 11 8 0 Technical Specifications Steam Trap Compatibility All mechanical steam traps 1 2 12 5mm steam li
5. e to Channel 2 of the WSTM Please note installation of the WSTM must be performed by a qualified technician For safety reasons personal protective equipment should always be worn during installation of the WSTM due to the presence of live steam Cypress Envirosystems Doc 152 10104 01 Rev 1 0 WSTM User Manual Page 9 5 0 Operation 5 1 Configuration Configuration of the WSTM must be performed by a qualified technician See Section 10 0 Support for details 5 2 Turning the WSTM On and Off To turn on a WSTM connect the external power terminal connector When the device is first powered on the LED lights will turn on in sequence To turn off the WSTM disconnect the external power terminal connector 5 3 Setting Sampling Rates Manual instantaneous reading To take a one time reading press the Function button for less than 2 seconds The green LED light will flash to indicate that data has been collected Routine data collection Whenever the WSTM is on it samples based on the routine data collection rate This rate is between 0 and 65535 seconds or approximately 18 hours This value is defined by the user and can be changed through the Cypress Envirosystems Web Console Preprogrammed short term data collection intervals n addition to the routine data collection rate there are two pre programmed short term data collection intervals associated with the WSTM FAST The FAST sample mode collects data at a 5 second inter
6. event is Cypress Envirosystems liable to anyone for any indirect special or consequential damages 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 Table of Contents PEE OGCIUGTION sc ch toe REN 4 Safety Preca ONS uetan iena is do Dv Detestubcn A a a aa 4 DescHDEHOomer the WST M eiin aa iN a a T 4 3 1 THEO Or OPEO E E 5 3 2 CONMECHIONS NUT TIU D 7 3 3 Sample colection o ELT 7 3 4 Cypress Envirosystems Monitoring SYSteM ccccccccscccseccscceeccssceeceescseesseesseeees 8 3 5 RETE 2 FO Cle ian an NOE ROR Rees MEN NT A Dco Fa Feu ene ee Reena en Ter 8 SUID eL 9 4 1 COMO OMI i E E E Gamers eenanens E TEN 9 4 2 Installation OVERVIOW oasen eraa a A NATA OA AO A er Ua PE acne 9 OPE HON onu a T a E E 10 5 1 COME E JHO stata dpa PME en eR nom cin one roe ear err ee Ree eee ere 10 5 2 Turning the WSTM Omand Off vti er E Sea nuce vid upto la yv e ations eee 10 5 3 Setting sampling RIES ned ini Gc so ve audiant Grad R eee MEM eU 10 5 4 WSTM onriguration WO Coit sisted consis hh de ad b e aut e vea Eva Gs ue i De e On a 10 Care ang MIIDte nale Base acento eo uh aa ca neta AET EN 11 6 1 CAO RALION MET T sian eaat enya A 11 6 2 Bee CCCI MHI mo ERE 11 TETEOUA OSS NOO ENS anaanatae a orbe ic chalice ree Mud ne o Code Saal Sa aan ee 11 TecHnNE Sped RIORUM 12 PROGU CLD ISD Oa PERRO TEE Pr 12 SUPPO MAN a a a E 12 Warranty Norma HOi a E E MO Ed Cio 12 1 0 Introduction Thank you for purchasing this Wireless Steam Trap Monito
7. ne and up Max Steam Pressure 800 psi 55 bar Data Capture Rate User configurable Thermocouple Type K 32 F to 2012 F 0 C to 1100 C Max Thermocouple Length 5ft 1 5m standard length Custom lengths available upon request Wireless Frequency 2 4GHz Direct Sequence Spread Spectrum 100mW peak output Wireless Range Up to 1600 ft 488 m high interference immunity extendable with repeaters Wireless Protocol Cypress Semiconductor s highly optimized industrial DSSS radio and protocol Integrates robust security antenna and frequency diversity optional encryption and minimal interference with existing wireless systems for additional details please see FAQ at www cypressenvirosystems com Approvals FCC Class B compliant RoHS ETSI compliant Power Supply Two 3V lithium batteries Battery Life gt 3 years approximate Humidity 10 99 RH non condensing Operating Temperature 4 F to 158 F 20 C to 70 C Storage Temperature 40 F to 185 F 40 C to 85 C Enclosure Rugged extruded aluminum industrial chassis optional NEMA4 IP66 enclosure Dimensions 5 7 x 2 2 x 1 6 145mm x 57mm x 42mm Weight 0 51 Ibs 230g 9 0 Product Disposal The WSTM is recycled by Cypress Envirosystems Contact a service technician or Cypress Envirosystems headquarters to recycle the WSTM See Section 10 0 Support for details 10 0 Support For additional support including configuration maintenance and troubleshooting plea
8. r WSTM Please read this guide thoroughly before using the WSTM The WSTM is not a stand alone product See Section 3 5 Related Products for details 2 0 Safety Precautions e Do not immerse the WSTM in water e Always wear personal protective equipment appropriate to the system the WSTM is being installed on e Do not try to repair yourself as it contains no user serviceable parts Contact a qualified service technician for repairs See Section 10 0 Support for details 3 0 Description of the WSTM The Cypress Envirosystems Wireless Steam Trap Monitor WSTM is designed to monitor the functionality of a steam trap and transmit the data to a PC or data acquisition system The WSTM has two input channels and is battery powered Installation is designed to be non invasive Figure 1 Wireless Steam Trap Monitor Cypress Envirosystems Doc 152 10104 01 Rev 1 0 WSTM User Manual Page 4 The following diagram describes the various components of the WSTM WSTM Front Panel WSTM Back Panel A B C D E F 3 1 Theory of Operation Sensor input terminal strip External power terminal strip LED indicators Function button Radio antenna connector Programming Expansion port Figure 2 WSTM Schematic The WSTM monitors steam trap functionality using a proven time tested method measuring the temperature at the inlet and outlet of the steam trap Analysis of the steam trap inlet and outlet temperatu
9. res as well as the differential temperature indicate the functionality of the steam trap For a properly functioning trap the inlet temperature will be equivalent to the saturated steam temperature for the operating pressure set point The outlet temperature of the trap will be equivalent to the temperature of the condensate typically just under the boiling point of water Note Expected steam and condensate temperature are functions of pressure If the outlet of the trap is under backpressure e g the steam trap outlet is connected to a pressurized condensate tank the boiling point of water will be higher Table 1 shows a sample of steam and condensate pressure temperature correlations Cypress Envirosystems Doc 152 10104 01 Rev 1 0 WSTM User Manual Page 5 Saturated Steam Inlet at X pressure Inlet Temperature Approx saturated steam temperature at X pressure Outlet Temperature E Less than boiling point of water at Y backpressure Condensate Outlet with Y Backpressure Figure 3 Steam Trap Operation Schematic Saturated Steam Boiling Point of Water i 1 10 Table 1 Steam and Condensate Pressure Temperature Correlation Steam traps have two failure modes failed open or failed closed Table 2 summarizes the expected temperature profile for the failure modes of a steam trap Failed open A failed open steam trap indicates a blown trap that is leaking steam This failure mode can result in increased energy cost
10. s due to the loss of steam The indicators for this failure mode are e The steam trap outlet temperature is greater than the boiling point of water indicating the presence of steam on the outlet of the trap e The differential temperature between the inlet and outlet of the steam trap is less than the differential for a properly functioning trap Failed closed A failed closed steam trap indicates a blocked trap that is building up condensate in the system Condensate buildup in a steam system can reduce the efficiency of the steam generation system Additionally significant condensate buildup can also lead to pipe damage caused by water hammer The indicators for this failure mode are e The steam trap inlet temperature is significantly lower than the saturated steam temperature indicating the presence of condensate on the inlet of the trap e The differential temperature between the inlet and outlet of the steam trap is less than the differential for a properly functioning trap Cypress Envirosystems Doc 152 10104 01 Rev 1 0 WSTM User Manual Page 6 Scenario Inlet Temperature Outlet Temperature Functioning Trap At saturated steam temperature Just below the boiling point of water At or above saturated steam temperature Blocked Trap Below boiling point of water Below the boiling point of water Off or Bypassed Trap Ambient temperature Ambient temperature Table 2 Steam Trap Temperature Profiles 3 2 Connections
11. se contact us Cypress Envirosystems Inc 198 Champion Court San Jose CA 95134 1 888 987 3210 Email cys_support cypress com 11 0 Warranty Information Every product comes with a full one year parts and labor warranty Cypress Envirosystems monitoring of battery status product status and potential communications packets are included during this period so that proactive service can be provided to our customers Cypress Envirosystems Doc 152 10104 01 Rev 1 0 WSTM User Manual Page 12
12. val for a 5 minute duration The WSTM can be placed into the FAST sample mode using the Function button 1 Pressthe Function button The green LED will illuminate 2 Hold the Function button until the yellow LED illuminates 3 Release the Function button To cancel the FAST sample mode once it has been initiated press the Function button The yellow LED will flash to indicate that the sample mode has been cancelled MEDIUM The MEDIUM sample mode collects data at a 30 second interval for an 8 hour duration The WSTM can be placed into the MEDIUM sample mode using the Function button 1 Pressthe Function button The green LED will illuminate 2 Aftertwo seconds the yellow LED will also illuminate 3 Hold the Function button until the red LED illuminates 4 Release the Function button To cancel the MEDIUM sample mode once it has been initiated press the Function button The yellow LED will flash to indicate that the sample mode has been cancelled 5 4 WSTM Configuration Mode The Configuration mode is primarily restricted and for use by qualified service technicians to configure and install the WSTM The WSTM can be placed into the Configuration mode using the Function button 1 Pressthe Function button The green LED will illuminate 2 Aftertwo seconds the yellow LED will illuminate Cypress Envirosystems Doc 152 10104 01 Rev 1 0 WSTM User Manual Page 10 3 After an additional two seconds the red LED will illumin
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