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Operating manual for the VISATRON VN2020

V2.0 12/2021 EN

Page

21

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

5. Safety and protection measures

VN2020-series oil mist detectors are manufactured according to Schaller Automation

’s high

quality standards and are tested in strict factory tests. The safety instructions and warnings
must be observed by the operator to ensure that the device operates smoothly and without
problems. These instructions are identified in the operating manual with the following symbols.

CAUTION!

For safe and proper use, read the operating manual and other documents
accompanying the product carefully and keep them for future reference.

5.1. Intended use

The task of the oil mist detector is to prevent explosions in the 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 of oil mist in crankcases and to protect
against oil mist explosions on large engines (gas, diesel and duel fuel).

When used on large motors that require explosion protection, an oil mist detector with
explosion protection marking must be used.

When used on large engines with mandatory approval by shipping classification societies, an
oil mist detector with corresponding class approval must be used.

The safety instructions must be observed.

5.2. Foreseeable misuse

The oil mist detector must not be installed without the use of suction funnels.

Unauthorised persons must not install or maintain the oil mist detector.

The oil mist detectors must  not be used in potentially explosive atmospheres without ATEX
approval.

The  installation  kit  components must  not  be  installed  other  than  as  shown  in  this  operating
manual and the applicable installation kit drawing.

➔

Applications not described in this manual are not allowed!

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Содержание Visatron VN2020

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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