Pyroban Gascheka duo System 5000 User manual

Copyright Pyroban Ltd. Issue 1 Page 1 of 32
Part number PM1083ENG
Gascheka duo™System
Operation - Installation - Servicing
DATE CHANGE
07.04.2015 Initial release
10.09.2015 Update to installation instructions
©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, photocopying or
otherwise, without prior permission from Pyroban Limited.
Pyroban Ltd
Dolphin Road
Shoreham by-Sea
West Sussex
BN43 6QG
Telephone: [phone]
www.pyroban.com
E-mail: [e-mail]

Copyright Pyroban Ltd. Issue 1 Page 2 of 32
Part number PM1083ENG
Contents
Operation - Installation - Servicing....................................................................................................1
Introduction..........................................................................................................................................3
Pellistor Head - De-activation by contamination ...........................................................................3
Contact information .......................................................................................................................4
System Overview...........................................................................................................................5
Components..................................................................................................................................6
Limitations of Use..........................................................................................................................8
Warnings related to operational use..............................................................................................9
Operating instructions......................................................................................................................10
Display Indicators ........................................................................................................................10
Pre-start Checks..........................................................................................................................10
Starting Gascheka duo................................................................................................................11
Use of Dallas 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 for Installation:...................................................................................................16
Location of Components .............................................................................................................17
Control Unit..................................................................................................................................17
Gas Sensing Head ......................................................................................................................17
Test Gas Cylinder........................................................................................................................18
Relay Unit....................................................................................................................................19
System Connection .....................................................................................................................19
Servicing.............................................................................................................................................24
Routine Servicing ........................................................................................................................24
Replacement of Fuses ................................................................................................................24
Annual Safety Audit.....................................................................................................................24
Trouble shooting guide.....................................................................................................................25
Appendix 1 – Specification...............................................................................................................29
Appendix 2 – Spares .........................................................................................................................30
Appendix 3 – pellistor head relative response...............................................................................31
Appendix 4 – infrared head relative response................................................................................32

Copyright Pyroban Ltd. Issue 1 Page 3 of 32
Part number PM1083ENG
INTRODUCTION
This manual contains instructions on Installing, Operating and Servicing Pyroban’s Gascheka
duo product.
Gascheka duo offers real time flammable gas detection with automatic equipment shutdown.
IMPORTANT INFORMATION
Adding Gascheka duo to equipment will not change the hazardous area rating of the
equipment on which it is installed. Further modification, testing and certification by a
recognized testing laboratory will be required to change the equipment’s hazardous
area rating.
IMPORTANT INFORMATION
The Pyroban Pellistor Gas Sensing Head has a high level of poison resistance, but it
may be irreversibly damaged by certain materials. These materials will increase the
replacement 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 compounds
•Organic phosphorous containing compounds
The Pyroban Infrared Gas Sensing Head is not affected by these materials.
The Pellistor and Infrared Gas Sensing Head will not detect the above materials.
IMPORTANT INFORMATION
Operation of the Pyroban Pellistor Gas Sensing Head may be temporarily impaired by
other materials. Normal operation may be resumed after a period of operation in clean
air.
Material that might temporarily impair proper functioning of the Pellistor Gas Sensing Head
includes:
•Hydrogen sulphide and organic sulphur containing compounds
•Halogenated hydrocarbons such as refrigerants
The Pyroban Infrared Gas Sensing Head is not affected by these materials
The Pellistor and Infrared Gas Sensing Head will not detect the above materials.

Copyright Pyroban Ltd. Issue 1 Page 4 of 32
Part number PM1083ENG
.
Contact information
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
United Kingdom
Phone: +44
(0) 1273 456800
E
-mail: [e-mail]
www.pyroban.com

Copyright Pyroban Ltd. Issue 1 Page 5 of 32
Part number PM1083ENG
System Overview
Gascheka duo is a ‘flammable-gas detection system’ for use on industrial vehicles. The system
will warn the vehicle operator if gas levels rise above 10% LEL* propane and will shut the
vehicle down if levels rise above 25% LEL propane.
For assured reliability, Gascheka duo has an automated gas test, which is performed every
time the system is activated from sleep mode. This is generally intended to be once a day at
the beginning of a shift. The vehicle cannot be used until the test is 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 keys is provided with the system kit. The driver keys enable a
choice of power saving modes. The supervisor key will re-activate the vehicle if a gas shut
down has occurred and should be appointed to the local facility official responsible for site
safety.
The system kit includes pre-made leads for interconnecting the main components to facilitate
installation. Infrared or pellistor gas sensing heads can be specified depending on the potential
gases that may be present.
* LEL (Lower Explosion Limit); the weakest mixture of gas in air that will support an explosion.

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Part number PM1083ENG
Components
The Gascheka duo system consists of the following major components.
Relay Unit
The Relay Unit is the wiring interface with the vehicle. Battery
power is fed into the Relay Unit to power the Gascheka duo
system. A volt free relay contact enables shutdown of the
vehicle. A second volt free relay contact facilitates a time
delayed shutdown for applications where the vehicle must be
brought to a controlled stop before the vehicle is shut down.
Control 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.
Pellistor gas detection head
The Gas Detection Head (Infrared or Pellistor) monitors the
concentration of flammable gas and signals the Control Unit.
Before each use the system performs mandatory start up
diagnostic test, during which
the Control Unit introduces a
sample of calibration and test gas into the Gas Sensing Head.
This check process confirms the correct operation of the Gas
Sensing Head before each use of the vehicle.
If this test is failed, the equipment will not be able to operate.
Infrared gas detection head

Copyright Pyroban Ltd. Issue 1 Page 7 of 32
Part number PM1083ENG
Test gas cylinder, regulator
and pressure gauge
The 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 applied to the
Control Unit to control the Gascheka duo system. Colour-
coded keys are provided with the Gascheka duo.

Copyright Pyroban Ltd. Issue 1 Page 8 of 32
Part number PM1083ENG
Limitations of Use
IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY PYROBAN, THE
PROTECTION PROVIDED BY THE GASCHEKA DUO MAY BE IMPAIRED.
IF THE GASCHEKA DUO FAILS TO OPERATE, OR IF IT SHUTS THE VEHICLE DOWN
WHILE IN OPERATION, DO NOT ATTEMPT TO RESTART UNTIL PERMISSION HAS BEEN
GRANTED BY THE PERSON IN CHARGE OF SITE SAFETY.
The Gascheka duo system automatically checks for the correct operation of the Gas Sensing
Head during each start-up. If the gas test consistently fails due to an inhibited or poisoned gas
sensing elements, you will be required to replace the Gas Sensing Head (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
present.
The Gas Sensing Head(s) must be protected when the vehicle is cleaned or when silicone is
being used to spray lift chains or other parts.
The Gas Sensing Head(s) must be protected in cases where a component of anti-seize sprays
used on the equipment contain silicone.
Gascheka duo does NOT offer any user adjustable settings or controls. The shutdown alarm is
locked in at 25% LEL propane. The response to other gases is listed in Appendix 3.
Gascheka duo should not be used in oxygen enriched or oxygen deficient atmospheres.
Gascheka duo must receive its electrical supply from lead acid batteries or an equivalent low
impedance DC voltage source.

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Part number PM1083ENG
Warnings related to operational use
•Relay unit connections – each terminal shall carry only one conductor between 0.5mm2
and 2.5mm2or 1.5mm by 2.4mm.
•The infrared gas sensing head, pellistor gas sensing head and Control units are not
user serviceable. The Relay unit is not serviceable except for the fuses which may be
replaced as follows.
•Fuse F1 – Fuse element T3.15A 5x20mm.
•Fuse 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 must be correctly set to ‘12V’ or
‘24V to 96V’ prior to operation.
•Warning – Extended operation of the system below normal battery voltages could
impair the operational function of Gascheka duo.
•Warning – the Control unit and Relay unit must be mounted in a location with a low risk
of mechanical impact.
•Warning – the Control unit and Relay unit must only be cleaned with a damp cloth.
•The Relay unit cable gland diameter accommodation is 5.0mm to 8.0mm.

Copyright Pyroban Ltd. Issue 1 Page 10 of 32
Part number PM1083ENG
OPERATING INSTRUCTIONS
Display Indicators
Note: Not all indicators on the Control Unit are relevant to Gascheka duo.
The Operator's responsibilities are restricted to the actions described in this section of the
manual. The Operator should not perform any servicing or maintenance, remove any covers or
replace fuses. Fuse replacement should be carried out by a suitably qualified/experienced
service engineer.
Pre-start Checks
1. Carry out any pre-start checks recommended 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 cylinder is turned to the ON position and
that the cylinder is not empty.
If there is any doubt as to the satisfactory condition of the vehicle or Pyroban
equipment, the Person in Authority must be consulted and any faults rectified
before the vehicle may be used.
4. Switch on the Gascheka duo isolator. Confirm that the green power indicator on
the Control module is lit.
Dallas receptacle
7 segment status
indicator
Gas Warning
Indicator
Vehicle
Operational
Indicator
Refer to
Manual
Indicator
Power Indicator
Gas Test progress
Indicators

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Part number PM1083ENG
Starting Gascheka duo
Before the vehicle can be operated, the Gascheka duo flammable-gas detection
system must go through a self-test gas response and calibration check.
1. Place the blue (or green) Dallas Key onto the receptacle on the Control Unit. A
tone will be heard and all indicators on the Control Unit will be illuminated
momentarily to confirm correct operation of the sounder and lamps.
2. The gas test progress indicators (green 1, 2 and 3) will illuminate in sequence as
Gascheka duo carries out an automatic gas test and calibration. This start-up
sequence takes approximately 90seconds for the pellistor head or 30 seconds for
the infrared head.
3. The type of head fitted is displayed in the 7 segment display during the gas test,
once the head type has been determined (during a 20S learning period after
power-on). “I” for infrared and “P” for 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 activate the system by initiating a start-up gas test. These
same keys may also be used to return the system into the Sleep mode (vehicle disabled). The
system can be set up to enter the sleep mode automatically if the vehicle is not used for a
period of time (this is detected via a motion sensor). The standard "sleep" period is six hours if
the green key is used and one hour if the blue key is used. The blue key is intended for use on
powered vehicles with 12V (or automotive) batteries, where battery drain is an issue. To
recover from sleep mode, apply either key and the system will be taken through the warm up
and calibration tests.
If a shutdown alarm occurs due to flammable gas readings the red key must be used to reset
the system after which the green or blue key must be used to re-activate the system.
The red key should not be kept with the equipment, but be held by the person
responsible for site safety.

Copyright Pyroban Ltd. Issue 1 Page 12 of 32
Part number PM1083ENG
Operating the Vehicle
Once Gascheka duo is in the Drive mode , the vehicle can be operated as normal but
the operator must be made aware of the potential for the vehicle to stop automatically (with or
without a delay).
Gascheka duo will activate vehicle shutdown if the flammable gas threshold is reached or a
system fault is detected.
Depending on the vehicle characteristics the shutdown may 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 delay of up to 25
seconds may be set via DIP switches in the Relay unit.
If such a delay is implemented, the vehicle will be labelled accordingly. In the event of a
shutdown the vehicle should be brought to a controlled stop BEFORE automatic shutdown
occurs. A shutdown or imminent delayed shutdown is identified by operation of the sounder and
a red triangle (on solid).
Refer to the original vehicle operator manual for further guidance on operating the vehicle.

Copyright Pyroban Ltd. Issue 1 Page 13 of 32
Part number PM1083ENG
De-activating the System
During normal daily operations it is not necessary to de-activate the Gascheka duosystem until
the end of a shift.
The procedure for deactivating the system is as follows. Ensure the vehicle is stationary 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 indicator will be extinguished and the vehicle will be disabled
When the system is not being used it is recommended practice to switch off the Gascheka duo
isolator to preserve battery charge. This is especially important on vehicles with 12V electrical
systems
Turn off the test gas bottle valve.

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Part number PM1083ENG
Explanation of Vehicle Shutdown and Control Unit
Warnings
Key: Alarm sounder activated Flashing Display
1. Low level of gas or vapour detected. Gas detection of 10% LEL will cause
an audible and visible warning 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 do so.
2. High level of gas or vapour detected. Gas detection of 25% LEL will cause
an audible and visible warning to activate and the vehicle will be shutdown,
either immediately or after a short delay.
BRING THE VEHICLE TO A CONTROLLED STOP.
Inform the Person in Authority.

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

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Part number PM1083ENG
Preparation
Check the kit of parts supplied against the packing list in kit list:
Study the installation diagram with a view to siting the new Gascheka duo components and
cable runs on the vehicle.
The following cables carry incendive voltages and currents and MUST be routed within the
confines of the vehicle or mechanically protected from impact to prevent an ignition hazard.
•Power supply cable
•Cable from 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 Unit to Gas Sensing Head
Battery
Disconnect battery in accordance with vehicle manufacturer’s instructions prior to any
installation work taking place.
Recommended Tools Required for Installation:
Digital Voltmeter
Tap wrench
Taps 4mm, 5mm & 8mm
Drill to suit
Battery Powered Drill
Spanners - 8,10,13,17 & 19mm
Gas bottle regulator spanner
Hole cutter for Isolator Switch
Metric Allen Keys (2.5mm & 3mm)
Wire strippers
Wire Cutters
Crimp tool (Press Master RS 533-279)
Terminal screwdriver

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Part number PM1083ENG
Location of Components
Select positions for Gascheka duo components with a low
risk of mechanical impact and where the operation of the
vehicle, driver’s view, access to doors or covers etc. is not
compromised.
Control Unit
(a) Remove the bracket from the Control Unit and
choose a position that is visible and within easy
reach of the driver. Consider also, easy cable
access to the rear of the unit.
(b) Mark hole positions using bracket as template; drill
holes. Fit the bracket to the vehicle and secure with
four M4 screws, spring washers, plain washers and
nuts supplied.
(c) 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 sensing heads contain sensitive
electronic components and may break if
subjected to impact or dropped.
(b) Mount Gas Sensing Heads on the vehicle so
as to be readily exposed to any flammable
atmosphere but protected from mechanical
damage and environmental contamination
(dirt, water spray etc.). For solvent
applications the head should be mounted
close to the ground (max 0.6m).
(c) Mount the Gas Sensing Head between 20o
and 60o to the horizontal using the two
brackets and two M8 bolts supplied. Failure
to do this may cause the system to fail the
automated gas response test and
compromise response time.
Gas Head
Example of location
Bracket

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Part number PM1083ENG
(d) NOTE: Erroneous flammable indications and
shutdowns may be seen if the gas head is
located next to axle vents or screen wash
containers.
(e) Gas Sensing Heads must be protected when
cleaning the vehicle or using silicone based
lubricants or sealants (A plastic bag sealed
with tape is sufficient). Where such materials
are present 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 vehicle provides mechanical protection.
2. Position the Gas Bottle Mounting Clamps onto the
Bracket. Secure the bracket with two M8 screws, spring
washers, plain washers and nuts supplied. Alternatively
drill and tap mounting holes in suitable location using
bracket as template.
3. Fit the regulator to the cylinder.
4. Fit the test gas cylinder assembly to the bracket and
secure with clamps provided.

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Part number PM1083ENG
Relay Unit
5. Mount the Relay Unit Bracket to suitable location.
The Relay Unit should be fixed to the bracket by its
four mounting holes in the plastic moulding using M5
Cap Head screws with spring washers.
6. Allow reasonable access to remove the cover for
fuse replacement.
7. The enclosure may be mounted on a horizontal or
vertical surface, but the cable glands should not be
facing upwards in order to prevent the
ingress of water.
System Connection
8. Refer to the installation diagram for connections and best practice.
9. The Relay unit is supplied in 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: The 12V version brings in a voltage boost circuit to compensate for voltage drop
caused by engine cranking. Use of 815859 on a 12V system may result in system reset
when the engine is cranked.
Supply should be taken from a suitable point closest to the battery using the supplied fuse
holder and 5amp fuse.
The Isolator Switch should be installed in a suitable accessible position.
10. A 2-core x 1.5mm2cable is supplied for the power and
shutdown relay wiring.
If a replacement cable is used, this must be rated for the
maximum system voltage with a minimum 8A current
rating taking into account the ambient temperature.

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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