background image

 

 

Copyright Pyroban Ltd.                                                                              Issue 1 Page 20 of 32 

Part number PM1083ENG 

 

11.  Gascheka duo disables the vehicle by interrupting the 

power supply to a component such as a contactor or fuel 
relay. See wiring diagram for detail. This component used 
to facilitate shutdown is to be selected by the installer, 
however 

the switching capacity of the Relay Unit is 

limited to the values on the table on the installation 
diagram.

 If the load is greater than allowed by the table 

then a slave relay must be used. Wire via the cable 
glands provided. 

The ignition line is a popular line to 

interrupt with the Gascheka duo Relay, however note 
some components such as lights may not be isolated.

 

 

 

 

 

 

12. 

Delayed Shutdown 

may be chosen in addition to, or 

instead of normal shutdown. Delayed shutdown is 
typically chosen for safety control related items such as 
steering or brakes. Wire to terminal J5 and follow the 
guidelines on the connection diagram. The period of delay 
on this shutdown is installer settable, to a maximum value 
of 25 seconds, using the DIP switch on the PCB. Refer to 
the connection diagram for settings. If the load is greater 
than allowed by the table then a slave relay must be used.  

 

 

13.  Connect the power lead (7-core) to the Control Unit 

and route into the Relay Unit via the cable gland 
provided. Trim and terminate to connector J2.  

The system incorporates a motion sensor to facilitate 
an optional timeout back to Sleep mode if the vehicle 
is not used for a period of time. Decide whether the 
automatic timeout facility is required (1hr for blue 
key, 6hrs for green key).  

 

To activate timeout, the black wire of the 
Power lead should be connected to 
terminal J2/6 6 

 

To deactivate timeout, the black wire of the 
Power lead should be connected to 
terminal J2/6 7 

If timeout is not selected, Gascheka duo will remain 
in Drive mode indefinitely. The ability to shut the 
vehicle down will not be affected by either mode.  

 

 

 

 

J4 

J1 

 

J3

 

J5 

DIP 

SWITCH 

J2 

Summary of Contents for Gascheka duo System 5000

Page 1: ...nstructions COPYRIGHT 2017 All rights reserved No parts of this manual may be reproduced stored in a retrieval system or transmitted in any form or by any other means electronic mechanical photocopyin...

Page 2: ...allas keys 11 Operating the Vehicle 12 De activating the System 13 Explanation of Vehicle Shutdown and Control Unit Warnings 135 Installation 15 Installation Diagram 15 Preparation 16 Tools Required f...

Page 3: ...frequency of the Gas Sensing Head Materials that might damage the Pellistor Gas Sensing Head include Organic silicon containing compounds such as silicone fluids and greases Organic lead containing c...

Page 4: ...on For any questions or concerns about this or any other Pyroban products or services please do not hesitate to contact us Pyroban Ltd Endeavour Works Dolphin Road Shoreham by Sea West Sussex BN43 6QG...

Page 5: ...completed Gas calibration is performed using 0 5 propane in air contained in a 0 5 litre cylinder which requires periodic replacement This gas mixture is non flammable A set of driver and supervisor k...

Page 6: ...ol Unit The Control Unit receives the gas sensing head signal and controls the shutdown function of the Relay Unit The Control Unit also displays the various warning and shutdown modes to the operator...

Page 7: ...Test Gas Cylinder contains a non flammable mixture of propane in air which is used to verify correct operation of the Gas Sensing Head Electronic button key The Electronic Button Keys Dallas keys are...

Page 8: ...ad See recommended spares The Pyroban standard limited product warranty for Gascheka duo does not cover the Gas Sensing Head in environments where the materials that might damage the sensing head are...

Page 9: ...se F3 F4 Fuse element T2 0A 5x20mm The current rating of the relays is 2A maximum Install gas sensing heads between 20 and 60 to the horizontal Warning The voltage selection link in the Relay unit mus...

Page 10: ...by the vehicle manufacturer 2 Check the general condition of the vehicle and Pyroban equipment as defined in the Routine Servicing section of this manual 3 Ensure the valve on the Pyroban test gas cyl...

Page 11: ...pellistor 4 Start up is complete when you see a green tick on the Control module If the gas test is failed refer to the Trouble Shooting section Use of Dallas keys The green or blue keys are used to...

Page 12: ...inhibit all vehicle functions immediately or in some cases critical functions e g power steering may be preserved for a period of time so that the vehicle may be brought to a controlled stop A time de...

Page 13: ...ionary and properly secured according to the vehicle hand book From Drive mode illuminated place the green or blue electronic button key onto the receptor on the Control module The Drive mode indicato...

Page 14: ...ing to activate Vehicle is still operational Vehicle should be driven safely from the gas contaminated area Inform the Person in Authority DO NOT re enter the gas contaminated area until authorized to...

Page 15: ...Copyright Pyroban Ltd Issue 1 Page 15 of 32 Part number PM1083ENG INSTALLATION Installation Diagram...

Page 16: ...Relay Unit to Control Unit The remaining of the cable is non incendive but should be routed within the confines of the vehicle or mechanically protected to give reliable long term operation Control Un...

Page 17: ...Loosely mount the Control Unit support bracket install the Gas Head Lead to the Control Unit and secure Lead to the bracket d Fit the Control Unit Support Bracket 300814200 Gas Sensing Head a Gas sen...

Page 18: ...t in the environment the Pellistor Gas Sensing Head will not be covered by Pyroban warranty protection Test Gas Cylinder 1 Position the gas bottle where the pressure gauge is visible and where the veh...

Page 19: ...two voltage versions 815859 12V for use with 12V vehicles 815859 for use with 24V to 80V vehicles Warning Use of 815859 12V on voltages above 12V will result in permanent damage to the Relay unit Note...

Page 20: ...nal J5 and follow the guidelines on the connection diagram The period of delay on this shutdown is installer settable to a maximum value of 25 seconds using the DIP switch on the PCB Refer to the conn...

Page 21: ...xcess must be coiled and tied to the vehicle away from any moving parts within the confines of the vehicle 15 Connect the test gas pipe from the regulator on the test gas cylinder to the Gas Sensing H...

Page 22: ...valve on the bottle Disconnect the test gas pipe from the Gas Sensing Head 19 Place plastic bag bag that contains labels can be used over the Gas Sensing Head 20 Insert the test gas pipe into the pla...

Page 23: ...e driver s sight Add Job Identification number to label if required 26 Peel the protective backing off the Isolator Switch Sticker and position it adjacent to switch on the equipment Where delayed shu...

Page 24: ...nd that all fixings are secure Replacement of Fuses Fuses must only be replaced with the correct type as specified below Fuse Location Type F1 Main power fuse located in Relay Unit T3 15A 5 20 mm HBC...

Page 25: ...failure on the 7 segment status indicator The table below shows the types of failure and possible corrective actions 7 segment status indicator Type of fault Corrective action in each case power the...

Page 26: ...ban Ltd Issue 1 Page 26 of 32 Part number PM1083ENG Denotes that indicator is flashing OK Fault refer to manual Gas test phase 1 2 or 3 Flammable material in atmosphere 7 segment status indicator Soun...

Page 27: ...isor Dallas key on to the key receptor on the Control module Restart Gascheka duo in the normal way using either the green or blue key Automated gas test failure Investigation required Pyroban equipme...

Page 28: ...st will be passed and the Green tick illuminated so that the vehicle may be driven however the corresponding Test indicator will remain flashing Urgent servicing is required The Person in Authority mu...

Page 29: ...W max Humidity 15 to 90 RH non condensing Ambient Temperature The system is specified from 20 C to 50 C The System should be protected from high intensity solar radiation at high ambient temperatures...

Page 30: ...813 Gas Bottle 0 5l 450539 Gas tube 500886 Gas Sensing Head lead Part No Length m 804993 3 804993 5 804993 10 Kit Selected 804993 1 804993 15 804993 30 Option Power lead Part No Length m 804990 3 Stan...

Page 31: ...tone 36 31 Butane 31 12 Cyclohexane 41 22 Di methyl ethylene 33 89 DI Ethyl Ether 39 10 Ethane 21 79 Ethanol 28 24 Ethyl Acetate 41 22 Ethylene oxide 31 12 Ethylene 21 79 Heptane 43 57 Hexane 39 10 Is...

Page 32: ...VE RESPONSE Material LEL shutdown Cyclohexane 28 4 Ethanol 20 6 Ethyl acetate 58 8 Kerosene 53 4 Methanol 22 7 Isopropanol 40 4 n Heptane 31 2 n Propanol 36 4 n Propyl acetate 41 0 Butane 30 5 Isobuta...

Reviews: