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TLV TrapMan TM5N Instruction Manual

Steam trap management system diagnostic uni
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172-65592MA-07 (TM5N/TM5N-EX TrapMan Type P) 12 May 2022
Important: In order for the unit to perform highly accurate diagnosis, periodic maintenance
(function check) is necessary. A warning will be displayed on screen when
periodic maintenance is due (when the preassigned date for maintenance is
reached. ex: after 2 years). Please contact TLV at this time to request
maintenance.
If maintenance is not carried out, the unit will be automatically locked.
For details see 1.1 Periodic Required Maintenance.
Steam Trap Management System
Diagnostic Unit: TM5N/TM5N-EX
(Type P)
Copyright © 2022 by TLV CO., LTD.
All rights reserved

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Summary of Contents for TLV TrapMan TM5N

  • Page 1 (function check) is necessary. A warning will be displayed on screen when periodic maintenance is due (when the preassigned date for maintenance is reached. ex: after 2 years). Please contact TLV at this time to request maintenance. If maintenance is not carried out, the unit will be automatically locked.

  • Page 2: Table Of Contents

    Contents Introduction ............................3 1. Read Carefully Before Use ......................4 1.1 Periodic Required Maintenance ....................... 4 1.2 For Users of the TM5/TM5-EX and TrapManager (Ver. 3.3.x or earlier) ..........5 1.3 Safety Considerations ..........................6 1.4 Safety Precautions ........................... 7 1.5 Precautions for Use and Storage ......................
  • Page 3 11.3 Replacing the Main Battery ........................59 12. Troubleshooting .......................... 60 12.1 Error Messages ............................ 60 12.2 Troubleshooting ........................... 62 13. Specifications ..........................65 14. Calibration........................... 66 15. TLV EXPRESS LIMITED WARRANTY ..................67 16. Service ............................69 172-65592MA-07 (TM5N/TM5N-EX TrapMan Type P) 12 May 2022...

  • Page 4: Introduction

    Introduction Thank you for adopting the TLV TrapMan steam trap management system. This product has been thoroughly inspected before being shipped from the factory. When the unit is delivered, before doing anything else, please check the specifications and external appearance to make sure that all components have been received and there is no obvious shipping damage.

  • Page 5: Read Carefully Before Use

    When one of the following alerts is displayed on screen, as soon as possible, bring the unit to the nearest TLV representative, or contact TLV for further information. The TM begins counting when you turn on the power for the DAYS UNTIL REQ.

  • Page 6: For Users Of The Tm5/Tm5-Ex And Trapmanager (Ver. 3.3.X Or Earlier)

    2) To prevent your current database from being overwritten during the install, it will be automatically transferred to the following folder. Windows Vista, Windows 7, Windows 8 & 8.1 and Windows 10: C:/ProgramData/TLV/TrapManager/DatabaseOld/ Windows XP and Windows 2000: C:/Documents and Settings/All Users/ApplicationData/TLV/TrapManager/DatabaseOld/ 3.

  • Page 7: Safety Considerations

    1.3 Safety Considerations Read this section carefully and follow the instructions to ensure proper use of the unit. The precautions listed in this manual are designed to ensure safety and prevent personal injury to yourself and others as well as equipment damage. For situations that may occur as a result of erroneous handling, three different types of cautionary items are used to indicate the degree of urgency and the scale of potential danger and damage: DANGER, WARNING and CAUTION.

  • Page 8: Safety Precautions

    1.4 Safety Precautions 1.4.1 Charging Precautions WARNING Do NOT charge with other than specific incoming voltage (Ui: 4.5 V) and current (li: 300 mA). Charging with other than specific incoming voltage (Ui: 4.5 V) and current (li: 300 mA) may result in fire, damage to the unit or electrical shock. Use only a standard commercial power source.
  • Page 9 1.4.2 Battery precautions WARNING Do NOT attempt to dismantle the battery. Do NOT attempt to disassemble the battery under any circumstances. Battery fluid leakage may cause injury to the skin or damage to clothing. Use only eneloop AAA batteries. For the TM5N-EX (intrinsically safe), use only SANYO HR-4UTGB or Panasonic BK-4MCC (eneloop AAA) batteries.
  • Page 10 The main battery of TM may be replaced by the customer. Since the main battery is recyclable, dispose of it in an environmentally friendly manner and according to local regulations. For the backup battery, return unit to TLV for replacement. Including TM5N-EX (intrinsically safe), remove/replace batteries somewhere other than explosion hazard areas.

  • Page 11: Precautions For Use And Storage

    1.5 Precautions for Use and Storage The TM5N is not intrinsically safe. Use only the TM5N-EX in hazardous areas where intrinsically safe equipment is required. The TM5N-EX is approved for use in hazardous locations only while inserted in its leather case (case name: TM5N-LC-EX). Do not remove the case while in a hazardous location.

  • Page 12: Steam Traps That Cannot Be Evaluated

    Although more than 1,000 trap models can be tested with TM, those that operate under the following conditions cannot be evaluated: Steam traps that are affected by high velocity steam flow noise. Trap for TLV-COSPECT (Pressure reducing and control valve with built-in separator and steam trap) Trap for TLV-DC3S (Cyclone separator with built-in steam trap) Drip leg applications at pressure reducing stations and turbines.

  • Page 13: Functions And Features

    2. Functions and Features Makes it possible for anyone to analyze steam traps easily Measurement starts automatically as soon as the tip of the probe is pressed against the measurement point. After about 15 seconds, measurement stops automatically and the data is stored.

  • Page 14: Measurement Principles

    Data on the correlation between the intensity of ultrasonic waves generated and the amount of steam leakage has been collected by TLV using the Steam Loss Test Apparatus at TLV CO., LTD. headquarters. So far, data for over 100,000 cases has been collected in this ongoing process.

  • Page 15: Principles Of Condensate Backup Judgement

    3.2 Principles of Condensate Backup Judgement 3.2.1 Measuring inlet temperature of the steam trap If the steam trap is operating properly, the inlet temperature of the trap will be almost exactly the same as the saturation temperature of the steam pressure in that location. If blocked or undersized, condensate will collect at the trap inlet and the trap inlet temperature will drop.

  • Page 16: Measurement Position

    3.3 Measurement Position 3.3.1 Standard horizontal pipes Traps should be measured at the trap inlet, which may be at the bottom of the trap in some instances. Hold the probe perpendicular to the flat surface at the inlet and press firmly for 15 seconds.
  • Page 17 3.3.2 Standard vertical pipes Traps should be measured at the trap inlet, which may be at the bottom of the trap in some instances. Hold the probe perpendicular to the flat surface at the inlet and press firmly for 15 seconds.
  • Page 18 Traps should be measured at the trap inlet, which may be at the bottom of the trap in some instances. Hold the probe perpendicular to the flat surface at the inlet and press firmly for 15 seconds. The point at which the measurement is taken must be filed smooth with the file delivered with the unit.

  • Page 19: Part Names

    4. Part Names 4.1 TM Unit 4.2 Probe and Leather Case Leather Case (TM5N-LC-EX) Coiled Cord Used to protect theTM unit from Used to connect the probe to the TM unit. dirt and dust. WARNING Probe The TM5N-EX (intrinsically Pressed and held against the safe) must always be inserted in filed clean flat surface at the trap this leather case while used in...

  • Page 20: Function Keys

    4.3 Function Keys 4.3.1 Function keys DATA Used for data transfer with the PC. TRANS FUNC Used to tabulate inspection data and change settings. Used for entering detailed data on pipes and the operating INFO conditions for measured traps, etc. Used to scroll through the screens for recalling inspection data selecting INFO key items, registering/recalling trap model names.

  • Page 21: Preparing For Inspection

    5. Preparing for Inspection 5.1 Preparing for Inspection Before starting the inspection, you should prepare the TM hardware with the procedures indicated by the graphics below. Charge the battery Connect probe Turn on power FUNC Inspect Send/receive data Set default values 5.2 Charging the Main Battery for the TM Before starting the charging process, be sure to read "1.4.1 Charging Precautions".

  • Page 22: Connecting The Probe

    To charge 1) Press the Charge button on the charger. 2) After 1 minute the "Start" LED (green) will start to blink and main charging will begin. 3) Once charging is complete, the "Finish" LED (green) will start to blink. 4) Unplug the charger from the outlet, remove the charger plug from the TM.

  • Page 23: Turning The Tm Power On

    If the name displayed on screen is not that of the customer for the current inspection, either download the data again or consult the person in charge at TLV. If a blank screen is displayed, follow the steps in "5.6 Data Communications with the PC"...

  • Page 24: Data Communications With The Pc

    5.6 Data Communications with the PC With the TM switched OFF, unlock the connector cover on the side of the TM and remove the connector cover. TM5N-EX (intrinsically safe): Be sure to retain the cover screw in a safe place. The connector cover must be replaced and the screw secured in order to maintain intrinsic safety.

  • Page 25: Inspection Procedure

    6. Inspection Procedure Before attempting inspection, be noted that there are steam traps that cannot be evaluated. See "1.6 Steam Traps that cannot be Evaluated". Follow the steps below when measuring trap performance at the site: Turn the TM power ON. 2.

  • Page 26: Recalling The Control Number

    6.1 Recalling the Control Number Two methods are used to recall previously registered or downloaded control numbers. 1. Enter the control number directly and recall that number. (See "6.2 Entering the Control Number" for more information.) 2. Scroll through the registered control numbers. a.
  • Page 27 Entering the Control Number: Example To enter "A01" for the area number: NOTE: TRAP The same procedure is used to enter trap numbers, except you should press AREA instead of AREA 000-00000 1. Press . The cursor will blink at the first digit of the MODEL area number position.

  • Page 28: Using The Probe

    6.3 Using the Probe 1. To begin measurement, you must have satisfied the following requirements: You must set the date and time (see "8.4 Changing Settings"). The inspection date and time, important information for record keeping and analysis, are automatically recorded when the trap is measured. Confirm that the date and time are properly set and make any corrections necessary before continuing with your survey.

  • Page 29: Messages Displayed During Measurement

    6.4 Messages Displayed During Measurement The intensity of the detection level will be displayed in bar graph. ? ? ? ? ? ? TEMP. 150  C 15s Surface temperature 15 second measurement count The intensity of the detection level will be displayed in bar graph.
  • Page 30 CAUTION If the exact steam pressure is not known:  To find out the exact pressure directly in front of the trap, it is best to install a pressure gauge. If this is not possible, determine it as follows:  The TM is equipped with a function that selects the steam pressure equivalent to the measured surface temperature and displays this value.

  • Page 31: Condensate Load Factor

    6.6 Condensate Load Factor 1. After the pressure is entered, the screen for entering the CONDENSATE LOAD? condensate load factor for the measured trap will 1:? 2:MIN 3:MAX automatically appear. If you have selected the trap before, the cursor will blink over the condensate load factor. If you have newly created an entry for this trap, the cursor will blink over an initial value of "1:?"...

  • Page 32: Entering The Temperature Setting

    6.7 Entering the Temperature Setting You must enter the temperature setting only in the case of a temperature adjustable trap. After the pressure has been entered, the unit will prompt you to enter the temperature setting for the measured temperature adjustable trap. If no temperature setting has previously been entered, A01-00000 "70 C (150 F)"...

  • Page 33: Judgement

    7. Judgement 7.1 Recalling Judgements CALL Pressing toggles the display between the judgement and the model name. JUDGE A01-00000 A01-00000 MODEL J3X-21 MODEL J3X-21 CALL CALL CALL CALL JUDGE JUDGE JUDGE JUDGE A01-00000 A01-00000 150 C 302 F GOOD GOOD NOTE: It is possible to revise the judgement even after it has been finalized.

  • Page 34: Re-Judgement

    7.3 Re-judgement Once measurement has ended, automatic judgement can be performed again without pressing the probe against the trap. AREA TRAP Recall the trap number for re-judgement by pressing or by scrolling through the trap numbers using CALL Press to display the judgement. JUDGE SHIFT Press...

  • Page 35: Automatic Judgement Items

    7.4 Automatic Judgement Items GOOD: The measured trap has been judged to be functioning normally. LEAKING (S/M/L): The measured trap has been judged to be leaking steam. One of fifteen (15) levels will be displayed. BLOWING: The measured trap has been judged to be leaking steam above the level of an "L" leakage. LOW TEMP: The surface temperature at the inlet of the measured trap is less than 60% of the saturation temperature for the entered pressure.

  • Page 36: Manual Judgement Items

    7.5 Manual Judgement Items These items can be entered when modifying judgements. NOT IN S (Not in Service): The measured trap is not operating. VALVED OUT: The inlet or outlet valve to the steam trap is closed (no steam supplied). CFM REQ.

  • Page 37: Using The Function Keys

    8. Using the Function Keys 8.1 Using the Function Keys FUNC Pressing changes the mode to function mode and allows the following functions to be executed. FUNC To exit function mode, press again. : 8.2 Tabulate Inspection Results : 8.3 Search for Failed Traps : 8.4 Change Settings ＋...

  • Page 38: Searching For Failed Traps

    While using this function to view failed traps, the judgement results and trap information are also accessible. 8.4 Changing Settings Default values are set before the unit is shipped from the TLV factory. These settings should be changed only when necessary. FUNC to check the following settings.
  • Page 39 8.4.5 Date and time The date and time are preset to Japan time at shipping, but will be reset to the local time when the unit is connected to TrapManService.net. The date and time cannot be changed manually. 8.4.6 Reference value for LOW TEMP judgement This is the standard used for determining when the temperature is abnormally low.

  • Page 40: Automatic Initialization Of Settings

    8.5 Automatic Initialization of Settings Pressing resets the values to their factory default settings. A confirmation message will appear. Press to execute the operation. START INITIALIZE OK:ENT NO:FUNC FUNC Press to cancel the operation. The following items will be automatically executed: ・Inspection data will be cleared (deleted).

  • Page 41: Information Mode

    9. Information Mode 9.1 Displaying INFOrmation Mode INFO i: indicates that the mode is Press to change to information mode. set to INFO MODE In this mode, you can check and enter data for the control numbers for which a model i A01-00000 name has been entered.
  • Page 42 26. Display/edit upstream temperature 27. Display/edit condensate recovery temperature 28. Display/edit disturbance noise information 9.2.1 Display inlet pressure and temperature settings (temp. control traps only) This item is used to display the trap PRESS. PRESS. 05.5KG 05.5KG ---  C --- ...
  • Page 43 9.2.3 Display trap location information This item is used to display or edit the Data cannot be entered location in which the steam trap is installed. into this area. Up to 32 characters can be entered. LOCATION Bldg.1 Tires 2F Use alphanumeric characters for input.
  • Page 44 9.2.5 Display/edit tracing condition This item is used to select whether or not “Important TRACE CONDITION Tracing”, that is tracing with saturated steam, is 00:LOW TEMP necessary, depending on the control temperature of The cursor will blink indicating the heated material. that data can be entered.
  • Page 45 9.2.7 Display/edit line pressure LINE PRESSURE This item is used to enter the line pressure 05.0KG for the steam trap to be inspected. If you do not wish to enter or revise the The cursor will blink indicating value, press to move to the next that data can be entered.
  • Page 46 This item is used to select whether or not The code number and condensate condensate from the inspected trap is recovery status appear here recovered. If you do not wish to enter or revise the code, COND. RECOVERY 00:NO press to move to the next item.
  • Page 47 9.2.11 Display/edit operational frequency This item is used to display or edit the steam trap’s The code number and status appear here. operational frequency. If you do not wish to enter or revise the code, press OPERATION FREQ. to move to the next item. 00:GENERAL CALL The cursor will blink indicating...
  • Page 48 9.2.13 Display/edit install date This item is used to display or edit the The month of the install date appears here. The default date that the steam trap was installed. value is “00”. If you do not wish to enter or revise the value, press to move to the INSTALL DATE...
  • Page 49 9.2.15 Display/edit trap orientation The code number and piping This item is used to select the steam trap piping orientation appear here. orientation. If you do not wish to enter or revise the code, ORIENTATION press to move to the next item. 0:VERTICAL The cursor will blink indicating CALL...
  • Page 50 9.2.17 Display/edit connection specification This item is used to select the steam trap The code number and connection type appear here. connection type. If you do not wish to enter or revise the code, CONNECTION press to move to the next item. 00:SCREW PT CALL The cursor will blink indicating...
  • Page 51 9.2.19 Display/edit inlet valve information This item is used to display or edit Information The code number and status appear here. about the steam trap’s Inlet Valve. If you do not wish to enter or revise the code, INLET VALVE press to move to the next item.
  • Page 52 9.2.21 Display/edit outlet valve information This item is used to display or edit Information The code number and status appear here. about the steam trap’s outlet valve. If you do not wish to enter or revise the code, OUTLET VALVE press to move to the next item.
  • Page 53 9.2.23 Display/edit inlet pipe specification This item is used to display or edit the steam trap’s The code number and status appear here. inlet pipe specification. If you do not wish to enter or revise the code, press INLET PIPE SPEC. to move to the next item.
  • Page 54 9.2.25 Display/edit screwed connection face to face length This item is used to display or edit the The face to face length appears here in mm. face to face length for a steam trap with screwed connections. SCREW FTOF If you do not wish to enter or revise the 400 mm value, press to move to the next...
  • Page 55 This item is used to display or edit the The surface temperature surface temperature of the of condensate recovery condensate recovery piping at the piping appears here in C. outlet side of the steam trap. If you do not wish to enter or revise the COND RECVRY TEMP 40C value, press...

  • Page 56: Entering Text

    “D” and “F”. CAUTION Only letters and numbers may be entered. Letters are always entered as capital letters; lower case letters cannot be entered. TLV recommends that you enter text on the PC. 172-65592MA-07 (TM5N/TM5N-EX TrapMan Type P) 12 May 2022...

  • Page 57: For Added Convenience

    This can be used to add new traps for inspection to the data sent from the PC. It is (In this figure, 1257 has been convenient for adding new traps for inspection without entered to register TLV the need to enter trap codes. model J3X-21.) ...

  • Page 58: Model Search Function

    AREA TRAP being displayed, do not press Instead, press . This registers the model name without assigning it to a control number. A learning feature has been included in the Model Memory Function so that more frequently used models will be displayed before less frequently used models regardless of the registration number sequence.

  • Page 59: Using Accessories

    11. Using Accessories 11.1 Using the Earphone (TM5N (standard type) only) The earphone included with the unit can be used to listen to the noise of trap operation. To use the earphone, insert the earphone jack into the connector on the top of the unit. CAUTION Loud noises or vibrations have the potential to cause deafness.

  • Page 60: Replacing The Main Battery

    11.3 Replacing the Main Battery The main battery used by the TM is rechargeable, so it will almost never need to be replaced. If this becomes necessary for some reason, use the following procedure. CAUTION Use only eneloop AAA batteries. For the TM5N-EX (intrinsically safe), use only SANYO HR-4UTGB or Panasonic BK-4MCC (eneloop AAA) batteries.

  • Page 61: Troubleshooting

    12. Troubleshooting 12.1 Error Messages * UNTRANSMITTED * STORED DATA LOST Immediately after power ON TRANSMIT DATA RESTORE FROM PC 001-00000 During measurement **CHECK ERROR** #MEMORY FULL# COMMUNICATION During communications ERROR “B” mark lit Battery-related No. B 001-00000 MODEL J3X-21 12.1.1 Untransmitted data CAUSE Some data remains to be transmitted.
  • Page 62 Restore the data from the PC. Trap Codes and Master Codes, etc., can be restored by downloading them from the PC. If this procedure fails to correct the problem, contact your TLV sales representative. 172-65592MA-07 (TM5N/TM5N-EX TrapMan Type P) 12 May 2022...

  • Page 63: Troubleshooting

    When the unit does not operate as it should, check the following items. If the unit still does not function properly even after these items have been checked and corrective action has been taken, contact your TLV sales representatives with a description of the problem.
  • Page 64 12.2.6 The MODEL keys do not work Check the following and take the appropriate action. Is the cursor blinking at the area or trap number position? Press to confirm the control number and then try the operation. Is the "i" displayed indicating that the mode is set to INFOrmation mode? Is the "f"...
  • Page 65 12.2.13 Incorrect date and time is shown even after the setup It is possible that the capacity of the backup battery has declined. In that case, the TM unit needs to be returned to TLV. Please contact TLV. 172-65592MA-07 (TM5N/TM5N-EX TrapMan Type P) 12 May 2022...

  • Page 66: Specifications

    13. Specifications MODEL TM5N (Standard) TM5N-EX (Intrinsically Safe)  2G Ex ib B T3 Gb 2776 ATEX: DEMKO 12 ATEX 1212672X EN IEC 60079-0:2018, EN 60079-11:2012 cULus: Class , Zone 1, AEx ib B T3 Class , Zone 1, Ex ib B T3 File No.

  • Page 67: Calibration

    TLV recommends that the TM be recalibrated every 2 years or after 30,000 measurements, whichever occurs first, or when the probe tip becomes warped or damaged.

  • Page 68: Tlv Express Limited Warranty

    Subject to the limitations set forth below, TLV CO., LTD., a Japanese corporation (“TLV”), warrants that products which are sold by it, TLV International Inc. (“TII”) or one of its group companies excluding TLV Corporation (a corporation of the United States of America), (hereinafter the “Products”) are designed and manufactured by TLV, conform to the...
  • Page 69 WARRANTY NOT NEGATED HEREBY, AND ANY IMPLIED WARRANTY NOT NEGATED HEREBY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, DO NOT COVER, AND NEITHER TLV, TII NOR ITS TLV GROUP COMPANIES WILL IN ANY EVENT BE LIABLE FOR, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO LOST PROFITS, THE COST OF DISASSEMBLY AND SHIPMENT OF THE DEFECTIVE PRODUCT, INJURY TO OTHER PROPERTY, DAMAGE TO BUYER’S OR THE...

  • Page 70: Service

    16. Service For Service or Technical Assistance: Contact your TLV representative or your TLV office. In Europe: Tel: [49]-(0)7263-9150-0 Daimler-Benz-Straße 16-18, 74915 Waibstadt, Germany Fax: [49]-(0)7263-9150-50 Units 7 & 8, Furlong Business Park, Bishops Cleeve, Tel: [44]-(0)1242-227223 Gloucestershire GL52 8TW, U.K.

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