Schaller Automation Visatron VN2020 User manual

Oil mist detector
Visatron®VN2020 Ex
Visatron®VN2020 Ex
- Operating manual -
- 183001 -

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
Page 2of 106
SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
Page 3of 106
SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
Dear customer,
this operating manual is intended for all those who work/will work on/with the system
described here. They require knowledge of this operating manual to avoid faults in the system
and to operate the system without issues. They must therefore have knowledge of this
operating manual.
This operating manual applies to the following devices:
•Visatron® VN2020
•Visatron®VN2020 EX
The operating manual is part of the information for users when the system is placed on the
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) must be provided at the new location.
In all phases of life, all the information in the operating manual and/or the operating manuals
(including those of the supplier) must be observed. Please read the applicable sections in the
operating manual carefully before starting work.
We accept no liability for damage or malfunctions that are the result of failure to comply with
this operating manual. You must specify clearly who is responsible for the machine (the
operating company) and who may work on the machine (the operator).
The responsibilities of personnel involved in transport, installation, setup, adjustment,
operation, care, maintenance and servicing must be clearly defined.
The original version of the operating manual for the oil mist detector is provided.

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
Table of contents
1. Technical data and scope of delivery.................................................................7
2. Identification.....................................................................................................10
2.1. Product brand and type designation.................................................................10
2.2. Manufacturer....................................................................................................10
3. Product description and technical data.............................................................11
3.1. Product description..........................................................................................11
4. Oil mist detection system.................................................................................12
4.1. Oil mist detector VN2020.................................................................................13
4.2. Bracket ............................................................................................................17
4.3. Header pipes ...................................................................................................17
4.4. Engine wall screw connection and suction funnel.............................................18
4.5. Siphon blocks ..................................................................................................18
4.6. Hose lines........................................................................................................19
4.7. Canister 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
6.1. Safety precautions before use..........................................................................23
6.2. Unpacking, items included in delivery ..............................................................24
6.3. Approved drawing for the oil mist detection system..........................................24
6.4. Approved drawing for the oil mist detection system..........................................24
6.5. Connecting the compressed air supply ............................................................25
6.6. Connecting the electrical power supply............................................................26
6.7. Mounting holes on crankcase ..........................................................................26
7. Installation of the oil mist detector....................................................................27
7.1. Installing the oil mist detector with pre-assembled bracket...............................27
7.2. Installing the oil mist detector without bracket..................................................27
7.3. Installing the engine wall screw fittings and suction funnel...............................28
7.4. Installing the siphon block................................................................................31
7.5. Installing the canister siphon............................................................................36
7.6. Installing the pipes...........................................................................................38
7.7. Installation of the hose lines.............................................................................39

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
7.8. Installing the electrical connecting cable..........................................................39
7.9. Installing the Remote Indicator (optional).........................................................43
7.10. Starting up for the first time..............................................................................45
7.10.1.Setting the negative pressure at the measuring head ......................................45
7.10.2.Connecting the power supply...........................................................................48
7.10.3.Setting the sensitivity of the oil mist detector....................................................48
7.10.4.Function test during startup..............................................................................49
7.10.5.Checklist for startup.........................................................................................50
8. Operation and application................................................................................51
8.1. Display and alarm reset ...................................................................................51
8.2. Error diagnosis and troubleshooting.................................................................52
8.2.1. Error code –All LEDs off..................................................................................53
8.2.2. Error code 02 –Electronic module faulty..........................................................53
8.2.3. Error code 03 –Supply pressure measurement faulty......................................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 code 08 –Electronics temperature too high (> 75 °C).............................53
8.2.8. Error code 09 –Electronics temperature too low (< 0 °C) ................................53
8.2.9. Error code 10 –Ambient temperature too high (> 70 °C) .................................53
8.2.10.Error code 11 –Ambient temperature too low (< 0 °C).....................................54
8.2.11.Error code 12/17 –Internal memory checksum error .......................................54
8.2.12.Error code 13 –Optical sensor dirty –cleaning required..................................54
8.2.13.Error code 14 –Supply pressure too low .........................................................54
9. Maintenance and repair ...................................................................................55
9.1. Maintenance....................................................................................................55
9.1.1. Maintenance cycles for reliable operation........................................................55
9.1.2. Maintenance by the operator ...........................................................................57
9.1.3. Cleaning the light path (4,000 h)......................................................................57
9.1.4. Function test with smoke tube..........................................................................60
9.1.5. Replacing the filter of the filter control valve.....................................................63
9.1.6. Replace connection box seal...........................................................................64
9.1.7. Inspection of the oil mist detection system (16,000 h)......................................68
10. Repair..............................................................................................................68
10.1. Repair by the operator .....................................................................................68
10.1.1.Replacing the measuring head.........................................................................68
10.1.2.Replacing the terminal box...............................................................................72

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
10.1.3.Replacing the filter control valve ......................................................................77
10.1.4.Replacing the connecting hose........................................................................80
10.1.5.Replacing the seal for the inspection cover......................................................81
10.1.6.Replacing the seal for the mounting plate ........................................................83
10.1.7.Replacing the screw plug.................................................................................86
10.2. 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. Maintenance kit (4,000/8,000/12,000 hours)....................................................92
13.4. Cleaning kit......................................................................................................92
13.5. Service kit for VN2020 (16,000 hours/24 months)............................................93
14. Accessories for VN2020/VN2020 Ex................................................................95
14.1. U-pipe manometer...........................................................................................95
14.2. Differential pressure gauge..............................................................................96
14.3. Smoke test box................................................................................................96
14.4. Service box for VN2020...................................................................................97
15. List of figures ...................................................................................................99
16. Contact..........................................................................................................103
17. Change history...............................................................................................104
Index
Index
Change
Date
Changed by
1.0
Release
19 December 2019
Adams, P./Höh, S.
1.1
See change history
13 March 2020
Adams, P./Höh, S.
2.0
See change history
01 December 2021
G. Kornatz

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
1. Technical data and scope of delivery

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
Mechanical interfaces
Dimensions
Approx. 539 x 298 x 171 mm
Weight
12.41 kg
M1
External thread M16x1.5
Pipe connection, diameter size 10
M2
External thread M30x2
Pipe connection, diameter 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
Current consumption
Maximum 2 A
Supply E1
24 V DC
M25: Cable diameter 8-16 mm
Earthing via holes in base plate during
installation
Supply E2
M20: Cable diameter 5-13mm
Relay outputs
2 × “High Oil Mist Alarm”
1 × “Ready” (ready for operation)
1 × “Oil Mist Pre-Alarm”
(max. 60 Volt AC/DC, 1A)
Communication interface with monitoring
device
3-wire RS485, electrically isolated/
CANopen, electrically isolated
Recommended communication cable
LAPP UNITRONIC-FD CP (TP) plus
UL-CSA CABLE

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
Pneumatic interfaces
P1
External thread M16x1.5
Pipe connection, diameter size 10
Compressed air supply
Min. 2 bar
Max. 14 bar
Compressed air consumption
1.2 nm³/h ± 10%
Value may vary depending on customer
solution
Negative pressure
Position M4
Measure and adjust negative pressure
Min. -55mmH2O (-5.5 mbar)
Nom. -60mmH2O (-6 mbar)
Max. -65mmH2O (-6.5 mbar)
Air quality
ISO 8573-1:2010 - 6-4-4
Environmental conditions
Operating temperature
5 to 70 °C
Storage temperature range
-25 to 80 °C
Relative humidity
up to 95%
Protection rating
IP 54
Vibrations
5 - 25 Hz: 1.6mm peak
25 - 100 Hz: 40m/s² peak

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
2. Identification
2.1. Product brand 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 are not potentially explosive according to
ATEX
•VN2020 Ex for use in potentially explosive environments according to ATEX/IECEX
oATEX: II (2G) [Ex op is IIB T4 Gb]
oIECEx: [Ex op is IIB T4 Gb]
2.2. Manufacturer
Schaller Automation
Industrielle Automationstechnik GmbH & Co. KG
Industriering 14
66440 Blieskastel
Germany

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
3. Product description and technical data
3.1. Product description
The VISATRON® VN2020 oil mist detector from SCHALLER AUTOMATION is design to
protect large engines (gas, diesel and dual fuel) from oil mist explosions caused by the
spontaneous development of oil mist in the crankcase. It is part of a safety system to protect
the life and health of operating personnel and it prevents serious consequential damage.
The oil mist detector has been developed by SCHALLER AUTOMATION according to the
guidelines of the International Association of Classification Societies (IACS) IACS UR M10.
The oil mist detector works on the 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 crankcase atmosphere ensures that there are short
response times between the formation of the oil mist and the start of the oil mist alarm.
To avoid false alarms from spray oil, the intake system uses special Schaller Automation
suction funnels that can be used regardless of the direction of rotation of the motor. One
suction funnel is always required per suction point. This protects the system from the ingress
of splash oil.
During normal engine operation, the oil mist detector draws in any existing oil mist. This oil
mist can settle in the suction lines.
Schaller Automation uses a drainage concept at this point and returns the excess oil back to
the engine crankcase.
Additional draining components ensure that the system operates correctly under all operating
conditions.
This includes deployment in stationary power plants, as well as on ships with their static or
dynamic inclination angles.

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
4. Oil mist detection 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 installation setup for a VN2020 installation kit for a six-cylinder
engine.
Figure 1: Oil mist detection system VN2020
(1) Oil mist detector
(2) Bracket
(3) Engine wall screw fitting
(4) Canister siphon
(5) Pipe support
(6) Suction line for connection box
(7) Header pipe
(8) Suction line for engine wall
(9) Exhaust air pipe

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
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) Protective hood
(6) Air jet pump (Venturi principle)
(7) Type plate of the oil mist detector
(8) Type plate of the measuring head
(9) Display with error code
(10) Filter control valve
(11) Terminal box
4
9
8
7
6
10
1
2
3
5
11

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
Two product variants of the VISATRON® VN2020-series oil mist detector are available:
VN2020
VN2020 EX
Figure 3: VN2020
Figure 4: VN2020 EX
WARNING!
Explosion of the crankcase
Serious injury, including death
➔The oil mist 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 operate the oil mist detector in potentially explosive atmospheres classified as
II-/2G (Group II, Category 2G, equipment for atmospheres containing gas). The
requirements of IEC/EN 60079-0:2018 and IEC/EN 60079-28:2015 are met.
The differences between the VN2020 EX and the VN2020 are essentially indicated by the
following external features:
•Inspection cover: blue
•Type plate of the measuring head: EX symbol and EX marking instead of Schaller logo
•Type plate of the oil mist detector: additional EX symbol

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
The oil mist detector complies with classification II (2G) [Ex op is IIB T4 Gb].
*The brackets indicate that the device is installed outside the hazardous area () but emits optical radiation into
a hazard zone [ ].
Both devices are equipped with a measuring head (3), which includes an optical measuring
track under the inspection cover (4) and an LED display (9) to display all the important
informationfor the user under normal operating conditions. The measuring head(3) is attached
to the base plate (1) via a 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 mist enters the measuring
head via the header pipes. This is where the oil mist concentration is then measured in the
optical measuring track. The oil mist is then returned to the crankcase via the exhaust line.
The negative pressure for the suction system is generated by an air jet pump (6), which
operates on the Venturi principle. The electrical power supply is provided in a terminal box
(11).
Equipment Protection Level
Temperature Class (Maximum Surface Temperature) T4=135°
Gas Group-Ethylene (Classified according to the ignitability)
Protection Concept: Intrinsically safe Optical Radiation
Explosion protection symbol
Type of explosive atmosphere (G=Gas)
Equipment Category (Category 2, High protection, one fault)
Equipment Group (II: non-mining)
EU Explosive Atmosphere Symbol
+5°≤+70°C

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
Figure 5: Interface schematic
The device can be connected directly to the engine’s safety system. The interface contains
two oil mist alarm outputs, a pre-alarm output and a Ready signal.
During normal operation, the crankcase 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 interface in the measuring head.
The pre-alarm can also be parameterised. Using the factory setting, it is activated at 70% of
the main alarm threshold.
The two device types, VN2020 and VN2020 EX, can be purchased separately as oil mist
detectors or as a complete oil mist detection system (installation kit).
Engine Room
Control Room
Remote Indicator II
Alarm monitoring
system
Engine safety
system
Modbus RTU/CANopen
Remote Indicator RS485
Ready, pre-alarm, alarm signal
Oil mist concentration/status
4-20 mA

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
4.2. Bracket
When designing the installation kits, the bracket is adapted to the engine geometry and
designed for the applicable application for each customer.
The main task of the bracket is to accommodate the oil mist detector and to connect the oil
mist detection system to the engine housing.
4.3. Header pipes
Schaller Automation 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 installation kit.
The pipes are supplied in bent and in welded design. Depending on the application, the cutting
rings and union nuts for the corresponding screw connections are pre-assembled or supplied
loose.
Figure 6: Pipe with cutting rings and union nuts
Pipes are always adapted to the customer’s specific engine peripherals.
To be independent of fluctuations in the air pressure in the engineroom relative to the pressure
in the crankcase, the outlet of the air jet pump (exhaust pipe) must be fed back into the
crankcase.
Recirculation of the exhaust air mixed with oil into the engine room must be avoided.

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
4.4. Engine wall screw connection and suction funnel
An engine wall screw fitting essentially consists of two main components: the fitting body (1)
and a suction funnel (2).
Figure 7: Engine wall screw fitting
The oil mist containing 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 beforehand.
The fitting body allows for angular adjustment to accommodate the suction lines and forms the
connection between the header pipes, suction lines and the crankcase.
Schaller Automation offers engine wall screw fittings in various versions and specifically
depending on the engine peripherals.
4.5. Siphon blocks
The blocks are the alternative to the engine wall screwfittings. They are used where a drainage
concept using canister siphons is not possible because of the nature of the peripherals.
1
2

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
4.6. Hose lines
Hose lines can also be used as an alternative to the suction and exhaust air pipes.
The hose lines used by Schaller Automation consist of a 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
certificates can be downloaded from Schaller Automation’s homepage (www.schaller-
automation.com).
4.7. Canister siphon
During the suction process for an atmosphere containing oil mist, oil may settle in the suction
lines.
The canister siphon has the task of draining this settled oil in the header pipes before it clogs
or constricts the pipes.
Figure 9: Canister siphon
At least two canister siphons are therefore required per installation kit.

Operating manual for the VISATRON VN2020 V2.0 12/2021 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O. Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / Email: inf[email protected]e /
www.schaller-automation.com
4.8. Optional accessories
4.8.1. 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 Schaller Remote
Indicator II (see Figure 10).
The connection to the customer’s monitoring systems is via a three-wire RS485 bus line.
Figure 10: Remote Indicator II
Schaller Automation has also integrated the VISATRON® devices into the operator’s
automation system. A connection is possible via CANopen or MODBUS/RTU.