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.

Copyright Pyroban Ltd. Issue 1 Page 6 of 32
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.

Copyright Pyroban Ltd. Issue 1 Page 9 of 32
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