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Schaller Automation Visatron VN2020, Operating Manual

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Schaller Automation Visatron VN2020 Operating Manual Download Page 44

Operating manual for the VISATRON VN2020 

V2.0 12/2021 EN     

Page 

44

 of 

106

 

SCHALLER AUTOMATION

 

66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280 

Industrielle Automationstechnik GmbH & Co. KG

 

T

el. +49(0)6842-508

-

0

 

/ Fax -260 / Email: [email protected] /  

 

www.schaller-automation.com

  

 

 
 
Use a communication cable with a twisted and shielded 3-wire cable. 
SCHALLER  AUTOMATION  recommends  LAPPKABEL  UNITRONIC-FD  CP  (TP)  plus 
UL-CSA. Maximum cable length of 400 m. 
 
The connection between oil mist detector and monitoring device for standard applications is 
shown in the following wiring diagram (see Figure 52). 

 

 

Figure 52: Connection diagram for the VN2020 with Remote Indicator II 

 

 

 

400 m 

Max. length 

Summary of Contents for Visatron VN2020

Page 1: ...Oil mist detector Visatron VN2020 Ex Visatron VN2020 Ex Operating manual 183001...

Page 2: ...0 V2 0 12 2021 EN Page 2 of 106 SCHALLER AUTOMATION 66440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info s...

Page 3: ...he market and must be kept so that it is accessible to the operating company and the operator If the system is relocated the operating manual and or the operating manuals including those of suppliers...

Page 4: ...r siphon 19 4 8 Optional accessories 20 4 8 1 Remote monitoring system 20 5 Safety and protection measures 21 5 1 Intended use 21 5 2 Foreseeable misuse 21 5 3 Guide to symbols 22 6 Installation 23 6...

Page 5: ...ty 53 8 2 4 Error code 04 16 Measured value too high Measured value too low 53 8 2 5 Error code 06 Supply voltage not within permissible range 53 8 2 6 Error code 07 Reset button faulty 53 8 2 7 Error...

Page 6: ...Repair by Schaller Automation 87 10 3 Taking out of service and disassembly 87 11 Storage 87 12 Packaging 87 13 Spare parts 88 13 1 Spare parts list VN2020 88 13 2 Spare parts list VN2020 Ex 90 13 3 M...

Page 7: ...age 7 of 106 SCHALLER AUTOMATION 66440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info schaller de www scha...

Page 8: ...eter size 22 M3 External thread M30x2 Pipe connection diameter size 22 M4 Internal thread G1 4 M5 x4 through holes for screws M8 Electrical interfaces Power supply 18 31 2 V DC Nominal voltage 24 V DC...

Page 9: ...1 5 Pipe connection diameter size 10 Compressed air supply Min 2 bar Max 14 bar Compressed air consumption 1 2 nm h 10 Value may vary depending on customer solution Negative pressure Position M4 Measu...

Page 10: ...nd and type designation This operating manual is for the VISATRON branded series VN2020 oil mist detector The oil mist detector is available in two product variants VN2020 for use in environments that...

Page 11: ...Venturi principle to draw the oil mist atmosphere out of the crankcase Monitoring is implemented via an optical measuring track in the device s measuring head The active and permanent suction of the...

Page 12: ...n system An oil mist detection system referred to as an installation kit usually consists of the following for delivery and is configured to customer specifications Figure 1 shows the typical installa...

Page 13: ...42 508 0 Fax 260 Email info schaller de www schaller automation com 4 1 Oil mist detector VN2020 Figure 2 Oil mist detector VN2020 1 Base plate 2 Connection box 3 Measuring head 4 Inspection cover 5 P...

Page 14: ...detector is designed to draw in gases from a potentially explosive atmosphere for example the crankcase of a gas engine ATTENTION Explosion of the crankcase Serious injury including death Only operat...

Page 15: ...vibration protected mounting plate Oil mist containing crankcase atmosphere is drawn out of the crankcases via the engine wall screw fittings by the negative pressure generated in the unit The oil mis...

Page 16: ...se atmosphere is drawn in simultaneously at all suction points and tested in the measuring head There are two alarm thresholds The main alarm threshold can be parameterised using software via the USB...

Page 17: ...tion uses state of the art hydraulic components to draw in and transport oil mist atmospheres Only tubes according to DIN EN 10305 4 and fittings according to EN ISO 8434 1 are therefore used in the i...

Page 18: ...ng atmosphere is drawn in via the suction funnel and at the same time splash oil is prevented from getting into the header pipes Spray oil can clog the header pipes if it is not properly separated bef...

Page 19: ...hydraulic hose with an additional coating of galvanised wire mesh Figure 8 Hose line with wire mesh The hose lines are available with certificates from classification societies and authorities The cer...

Page 20: ...8 1 Remote monitoring system In compliance with IACS UR M10 the oil mist concentration and the status of the oil mist detector can be read from the oil mist detector at a safe location with the Schal...

Page 21: ...crankcase of large engines caused by a high concentration of oil mist such as can occur in the event of bearing damage within the large engine The oil mist detector may only be used for the detection...

Page 22: ...rty CAUTION Indicates a low risk hazard that if not avoided may result in minor or moderate injury WARNING Indicates a medium risk hazard which if not avoided could result in death or serious injury D...

Page 23: ...n of the crankcase Serious injury including death The oil mist detector with return of the crankcase atmosphere into the crankcase is suitable for a crankcase pressure in the range of 500 mmH2O under...

Page 24: ...er Automation provides you with a corresponding parts list for this purpose Dispose of the packaging materials in accordance with your local disposal regulations in the containers provided for this pu...

Page 25: ...o the oil mist detector ATTENTION Premature contamination of the light path The device may trigger a premature error message Comply with the quality requirements for compressed air The connection to t...

Page 26: ...2 and E3 see Figure 12 Figure 12 Front view of the terminal box DANGER Risk of electric shock Risk of injury Before connecting the electrical power supply lines you must ensure that there is no voltag...

Page 27: ...explosion protection valves ATTENTION The oil mist detector must not be painted varnished or otherwise altered A suitable means of transport e g crane must be used for installation and transport to t...

Page 28: ...Tools Open spanner width across flats 13 Open spanner width across flats 19 Open spanner width across flats 22 Open spanner width across flats 41 ATTENTION Danger due to flying parts or collision wit...

Page 29: ...Figure 15 Screw in sleeve and housing 2 Figure 16 Insert the suction funnel Screw the screw in sleeve with flat gasket and housing into the mounting thread of the crankcase At the same time align the...

Page 30: ...tomationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info schaller de www schaller automation com 3 Figure 17 Align the suction funnel 4 Figure 18 Connect line While tightening align the suct...

Page 31: ...Tools Allen key size 6 Combination spanner width across flats 10 Combination spanner width across flats 17 Filling pump with lubrication oil for filling the siphon block The siphon block consists of t...

Page 32: ...aps of the connecting unit and dispose of them Apply Loctite 243 to both threads 3 Figure 25 Mount the connecting unit 4 Figure 26 Insert the suction funnel Mount the connecting unit on the crankcase...

Page 33: ...igure 27 Remove protective caps 6 Figure 28 Push in the siphon block Remove the protective caps x4 from the screws on the siphon block and dispose of them Guide the siphon block over the pipe of the s...

Page 34: ...y the engine manufacturer and operate the pump mechanism until lubrication oil runs out of the side openings of the filling pipe Insert the filling pump into the oil return hole of the siphon block up...

Page 35: ...on oil 12 Figure 34 Remove filling pump Perform eight slow and steady pump strokes ATTENTION Excess oil can flow into the suction pipe This impairs monitoring of an engine block Do not pump more than...

Page 36: ...talling the canister siphon Material number 150939 Figure 35 Canister siphon 1 Canister siphon 2 Straight screw in socket L22 3 Union nut 4 Protective cap 5 Straight screw in socket L10 Required tools...

Page 37: ...sh the canister siphon 1 flush with the pipe attachment into the screw connection and initially fit the union nut hand tight ATTENTION Danger of part breaking Damage to parts or the engine Comply with...

Page 38: ...pes in the installation kits differ as follows Pipes with pre assembled cutting rings and union nuts Pipes without cutting rings and nuts Pipes with welded fittings including cutting rings and union n...

Page 39: ...onding specifications WARNING Blocking of hose lines due to sagging Monitoring by oil mist detector is impaired Install and assemble the hose lines according to the installation kit drawing 7 8 Instal...

Page 40: ...m Procedure for connecting the connecting line to the terminal box Figure 43 Terminal box front view 1 Figure 44 Cover and terminal box 2 Figure 45 Prepared connecting line Remove the cover of the ter...

Page 41: ...stor and replace installed resistors if necessary Connect the connecting line to the terminal blocks according to the wiring diagram See Table 1 5 Figure 48 Connecting earth example 6 Figure 49 Instal...

Page 42: ...RS485 A CAN H 6 B L RS485 B CAN L 7 GND RS485 GND CAN GND 8 NC1 Alarm system safety system Contacts COM1 and NO1 close in Ready mode 9 COM1 10 NO1 11 NC2 Alarm system safety system Contacts COM2 and...

Page 43: ...connected as a monitoring device for this purpose In the event of an oil mist alarm Schaller Automation strongly recommends as described in IACS UR M10 7 not to approach the engine or carry out inspe...

Page 44: ...schaller de www schaller automation com Use a communication cable with a twisted and shielded 3 wire cable SCHALLER AUTOMATION recommends LAPPKABEL UNITRONIC FD CP TP plus UL CSA Maximum cable length...

Page 45: ...easuring head 2 Inspection cover 3 Screw plug 4 U tube manometer digital differential pressure gauge 5 Quick release coupling 6 Water for U tube manometer To establish protection of the engine start u...

Page 46: ...uring head 1 2 Figure 54 Inspection cover with screw plug Unscrew the screw plug 3 on the inspection cover 2 of the measuring head 1 and set aside Figure 55 Inspection cover with quick release couplin...

Page 47: ...ly pressure This pressure must be between 2 bar and 14 bar Set 60 mmH2O 5 mmH2O To do this adjust the adjusting screw on the filter control valve until the specified negative pressure is reached on th...

Page 48: ...2 The LEDs on the display of the measuring head flash immediately after you switch on the power supply The oil mist detector now counts down for 30 seconds After the time has elapsed the System ready...

Page 49: ...dividually To do this hold the smoke tube directly under the suction funnel of the specific extraction point and perform 3 5 pumping strokes The resulting smoke should now be drawn out directly via th...

Page 50: ...ocks Are all siphon blocks filled with oil and all unused openings closed 4 If mounting with canister siphons Are all the canister siphons filled with oil 5 Is the negative pressure at the measuring h...

Page 51: ...is saved Figure 62 Example LED display with alarm The opacity is displayed on the LED level indicator on the right If the top LED comes on the opacity has reached exceeded the oil mist alarm threshol...

Page 52: ...None All LEDs off 8 2 1 00 Oil mist detector in operation 02 Electronic module faulty 8 2 2 03 Supply pressure measurement faulty 8 2 3 04 Measured value too high 8 2 4 06 Supply voltage not within pe...

Page 53: ...3 Error code 03 Supply pressure measurement faulty 1 Check the compressed air supply 2 Replace the measuring head Section 10 1 1 3 Contact service partner see appendix 8 2 4 Error code 04 16 Measured...

Page 54: ...bient temperature too low 0 C 1 Remove or relocate objects nearby that are cooling 8 2 11 Error code 12 17 Internal memory checksum error 1 Replace the measuring head Section 10 1 1 2 Contact service...

Page 55: ...efore maintenance and repair work and check the negative pressure in the measuring head see Section 7 10 1 after completing work WARNING Hazard due to electric current Switch off the power supply befo...

Page 56: ...measuring head X X X X 9 1 3 151482 Cleaning kit 3 Function test with smoke tube X X X X 9 1 4 151780 Smoke Test Box 4 Replace filter in filter control valve X X X X 9 1 5 155006 Maintenance kit for t...

Page 57: ...Only use Schaller Automation original spare parts 9 1 3 Cleaning the light path 4 000 h ATTENTION Premature failure of the oil mist detector Dirty parts increase the risk of equipment failure Clean p...

Page 58: ...n photodiode 6 Figure 68 Clean sealing surface Clean the photodiode Clean the sealing surface of the inspection cover seal 7 Figure 69 New inspection cover seal 8 Figure 70 Fit the inspection cover Po...

Page 59: ...6440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info schaller de www schaller automation com 9 Figure 71 Ti...

Page 60: ...ned Only carry out the function test with the engine at a standstill if the engine is running it will automatically stop or go into slow down mode 1 Figure 72 Remove the screw plug 2 Figure 73 Fit the...

Page 61: ...ke into the measuring head 6 Figure 77 Wait for the Alarm LED to come on Use the hand pump to pump the smoke into the measuring head The LED ALARM should come on within a few seconds 7 Figure 78 Remov...

Page 62: ...Box 1280 Industrielle Automationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info schaller de www schaller automation com Figure 80 Cancel alarm Figure 81 Device is ready for operation Cancel...

Page 63: ...0 Fax 260 Email info schaller de www schaller automation com 9 1 5 Replacing the filter of the filter control valve Material number 366717 Figure 82 Filter control valve Tools none 1 Figure 83 Loosen...

Page 64: ...and remove the filter Figure 86 Replace the filter Screw in the new filter anticlockwise and make sure that it is aligned for installation 5 6 Figure 87 Mount the filter cage Mount the filter cage in...

Page 65: ...compressed air supply to the oil mist detector Pull the compressed air hose off the right side of the venturi injector and push it to the side 3 Figure 92 Loosen the screw connection 4 Figure 93 Loos...

Page 66: ...n box Remove the seal Dispose of the seal in accordance with local disposal regulations Clean the connection box and the base plate in the area of the connection box Carefully clean both sealing surfa...

Page 67: ...el that it is in contact the screw sleeve cutting ring and union nut Hand tighten the remaining two hexagon screws Tighten the four hexagon screws crosswise to a torque of 4 5 Nm WARNING If you do not...

Page 68: ...10 1 1 Replacing the measuring head Material number 290044 VN2020 290045 VN2020 EX The information on the type plate must be provided for queries regarding measuring head spare parts Please use the r...

Page 69: ...ft side by turning it anticlockwise and unplug the connector Loosen the eight screws ATTENTION The measuring head may fall down Risk of impact and crushing Hold the measuring head firmly with one hand...

Page 70: ...screw connection Mount the measuring head with the flat seal Hand tighten the eight screws Tighten the screws crosswise to a torque of 4 5 Nm WARNING Too low a torque can have a negative impact on sea...

Page 71: ...Automationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info schaller de www schaller automation com 11 Figure 112 Switch on the power supply 12 Figure 113 Setting the negative pressure at th...

Page 72: ...GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info schaller de www schaller automation com 10 1 2 Replacing the terminal box Material number 290043 Figure 114 Terminal box Tools Cross head screwdriver...

Page 73: ...Switch off the power supply of the oil mist detector Loosen the union nut of the plug in connector on the left side by turning it anticlockwise and unplug the connector 3 Figure 117 Remove the cover 4...

Page 74: ...Wire break resistors 8 Figure 122 Remove screws Make a note of the value colour coding of the two wire break resistors Remove the four hexagon socket screws Remove the terminal box CAUTION Terminal b...

Page 75: ...rs 12 Figure 118 Insert the wire break resistors Take two suitable wire break resistors see step 7 from the supplied bag Insert the two wire break resistors into the circuit board Make sure that you i...

Page 76: ...ands plugs on the new terminal box For torque specifications see start of Section 10 1 2 Insert the cables through the cable glands 17 Figure 123 Place the wires in position 18 Figure 124 Tighten the...

Page 77: ...m 10 1 3 Replacing the filter control valve Material number 273456 273461 Figure 127 Filter control valve Tools Open spanner width across flats 19 Open spanner width across flats 10 Torque spanner up...

Page 78: ...ntrol valve Remove the four screw connections on the protective hood Remove the defective filter control valve CAUTION The filter control valve may fall down Risk of impact crushing Hold the filter co...

Page 79: ...el 49 0 6842 508 0 Fax 260 Email info schaller de www schaller automation com 7 Figure 134 Release pressure in the filter control valve 8 Figure 135 Set negative pressure Release pressure in the filte...

Page 80: ...hose Material number 290025 Figure 136 Connecting hose Tools None 1 Figure 137 Switch off the compressed air supply 2 Figure 138 Remove the connecting hose Switch off the compressed air supply Pull o...

Page 81: ...260 Email info schaller de www schaller automation com 10 1 5 Replacing the seal for the inspection cover Material number 356952 Figure 141 Seal for inspection cover Tools Allen key size 5 Torque wre...

Page 82: ...pose of the seal in accordance with local disposal regulations Clean the sealing surface of the inspection cover seal 5 Figure 146 Place the inspection cover seal in position 6 Figure 147 Fit the insp...

Page 83: ...for mounting plate Tools Allen key size 4 Torque wrench up to 5 Nm 1 Figure 151 Switch off the power supply 2 Figure 152 Remove the connecting hose Switch off the compressed air supply and electrical...

Page 84: ...ead 6 Figure 156 Place the seal in position Remove the measuring head and put it to one side Remove the flat seal Dispose of the seal in accordance with local disposal regulations Place the new seal s...

Page 85: ...com 9 Figure 159 Tighten plug in connector 10 Figure 160 Fit the connecting hose Attach the plug in connector Tighten the plug in connector securely by screwing clockwise Insert the compressed air ho...

Page 86: ...7 Replacing the screw plug Material number 366604 Figure 163 Screw plug Replace the screw plug if there is visible wear on the installed O ring Tool Allen key size 6 Torque wrench up to 20 Nm 1 2 Figu...

Page 87: ...ective or malfunctions please contact Schaller Automation or an authorised service partner See the Appendix for contact details Visit our homepage and find your nearest service partner https schaller...

Page 88: ...440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info schaller de www schaller automation com 13 Spare parts...

Page 89: ...356952 Seal for inspection cover 1 155006 155004 60 366717 Filter cartridge 1 155006 155004 70 273456 Filter control valve flow left to right 1 273461 Filter control valve flow right to left 1 80 3569...

Page 90: ...ON 66440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info schaller de www schaller automation com 13 2 Spare...

Page 91: ...56952 Seal for inspection cover 1 155006 155004 60 366717 Filter cartridge 1 155006 155004 70 273456 Filter control valve flow left to right 1 273461 Filter control valve flow right to left 1 80 35695...

Page 92: ...rs Material number 155006 Figure 168 Maintenance kit Maintenance kit for the VN2020 and VN2020 EX Item Material number Description Quantity 1 366717 Filter cartridge 4 2 356952 Seal for inspection cov...

Page 93: ...haller de www schaller automation com 13 5 Service kit for VN2020 16 000 hours 24 months Material number 155004 ATTENTION The device may trigger a premature error message Premature failure and loss of...

Page 94: ...info schaller de www schaller automation com Service kit for the VN2020 VN2020 Ex Item Material number Description Quantity 1 356951 Seal for mounting plate 1 2 356950 Seal for connection box 1 3 356...

Page 95: ...260 Email info schaller de www schaller automation com 14 Accessories for VN2020 VN2020 Ex 14 1 U pipe manometer Material number 270532 Figure 171 U pipe manometer Item Material number Description Qu...

Page 96: ...fo schaller de www schaller automation com 14 2 Differential pressure gauge Material number 151800 Figure 172 Differential pressure gauge Item Material number Description Quantity 1 436100 Differentia...

Page 97: ...0 Industrielle Automationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260 Email info schaller de www schaller automation com 14 4 Service box for VN2020 Material number 151906 The box contains all the...

Page 98: ...9 100ml bottle with low surface tension water 1 5 365193 Bellows 2 6 480824 Cheese head screw ISO 10642 M3 x 12 4 7 366655 Push in fitting QS G 6 1 8 366633 Push in fitting QS 10 6 1 9 366717 Filter c...

Page 99: ...ithout measuring connection 31 Figure 22 Siphon block with measuring connection 31 Figure 23 Connecting unit 32 Figure 24 Screws with Loctite 243 32 Figure 25 Mount the connecting unit 32 Figure 26 In...

Page 100: ...the adapter hose 60 Figure 74 Fit the flex hose 60 Figure 75 Connect the smoke tube and pump 60 Figure 76 Pump smoke into the measuring head 61 Figure 77 Wait for the Alarm LED to come on 61 Figure 7...

Page 101: ...ir supply 77 Figure 129 Remove the swivel fitting 77 Figure 130 Disassemble the filter control valve 78 Figure 131 Remove the filter control valve 78 Figure 132 Tighten the swivel fitting 78 Figure 13...

Page 102: ...air supply 85 Figure 162 U tube manometer 85 Figure 163 Screw plug 86 Figure 164 Remove the screw plug 86 Figure 165 Screw in the screw plug 86 Figure 166 Overview of the location of spare parts on th...

Page 103: ...ller automation com Schaller Automation LP 811 Shotgun Road Sunrise FL 33326 United States of America Phone 1 954 794 1950 Mobile 1 561 289 1495 Fax 1 954 794 1951 Email info schalleramerica com Schal...

Page 104: ...from 2 5 to 2 6 Nm p 82 Size of Allen key changed from 5 to 6 image updated p 83 Text and address of homepage added in Section 10 2 p 84 85 Item 70 filter control valve with flow direction right to le...

Page 105: ...3 Section 9 1 5 images text revised p 64 Section 9 1 6 images text revised p 68 Section 9 1 7 Text revised p 68 Section 10 1 1 images text revised p 72 Section 10 1 2 images text revised p 77 Section...

Page 106: ...use Detection and display of oil mist in large engines Serial number 0719025000 1219028000 Year of construction 2019 Marking 0637 2G Ex op is IIB T4 Gb Furthermore we declare conformity with further D...

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