Schaller Automation Visatron VN2020 User manual

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

Operation manual VISATRON VN2020 V1.1 03/2020 EN
Page 2/95
SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
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 is written in german.

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
Table of contents
1. Technical data and scope of delivery.....................................................................6
2. Identification...........................................................................................................9
2.1. Product and type designation.................................................................................9
2.2. The Manufacturer ..................................................................................................9
3. Product description and technical data.................................................................10
3.1. Product description..............................................................................................10
4. Oil mist detection system.....................................................................................11
4.1. Oil mist detector VN2020.....................................................................................12
4.2. Bracket ................................................................................................................16
4.3. Header pipes .......................................................................................................16
4.4. Engine wall connection and suction funnel...........................................................17
4.5. Siphon blocks ......................................................................................................17
4.6. Hoses ..................................................................................................................18
4.7. Pipe siphon..........................................................................................................18
4.8. Optional accessories............................................................................................19
4.8.1. Remote monitoring systems.................................................................................19
5. Safety and protection measures...........................................................................20
5.1. Intended use........................................................................................................20
5.2. Foreseeable misuse.............................................................................................20
5.3. Guide of symbols.................................................................................................21
6. Installation ...........................................................................................................22
6.1. Safety precautions before use .............................................................................22
6.2. Unpacking, items included in delivery ..................................................................23
6.3. Approved drawing for the oil mist detector system...............................................23
6.4. Work and preparations to be completed by the customer.....................................23
6.5. Establishing the compressed air supply...............................................................23
6.6. Establishing the electrical power supply...............................................................25
6.7. Mounting holes on crankcase ..............................................................................25
7. Installation of oil mist detector..............................................................................25
7.1. Mounting the oil mist detector with pre-mounted bracket .....................................25
7.2. Installing the oil mist detector without bracket......................................................26
7.3. Mounting of engine wall connections and suction funnel......................................27
7.4. Mounting siphon block.........................................................................................30
7.5. Mounting pipe siphon...........................................................................................33
7.6. Montage der Rohrleitungen..................................................................................35

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
7.7. Installation of hose lines.......................................................................................36
7.8. Installation of electrical connecting cable............................................................36
7.9. Montage Remote Indicator (Optional) ..................................................................40
7.10. Initial comissioning...............................................................................................42
7.10.1.Setting of negative pressure on measuring head................................................42
7.10.2.Connecting power supply.....................................................................................45
7.10.3.Setting the sensitivity of the oil mist detector........................................................45
7.10.4.Function test........................................................................................................46
7.10.5.Checkliste for comissioning..................................................................................47
7.11. Recommissioning.................................................................................................48
8. Operation and application....................................................................................48
8.1. Display.................................................................................................................48
8.2. Error analyze and troubleshooting .......................................................................48
8.2.1. Error code –All LEDs off......................................................................................50
8.2.2. Error code 02 –Electronic module faulty..............................................................50
8.2.3. Error code 03 –Airflow sensor faulty ...................................................................50
8.2.4. Error code 04 –Optical sensor faulty...................................................................50
8.2.5. Error code 05–07 –Internal error.........................................................................50
8.2.6. Error code 08 –Electronics temperature too high (> 75 °C).................................50
8.2.7. Error code 09 –Electronics temperature too low (< 0 °C) ....................................50
8.2.8. Error code 10 –Ambient temperature too high (> 70 °C) .....................................50
8.2.9. Error code 11 Ambient temperature too low (< 0 °C)............................................50
8.2.10.Error code 12 –Internal memory checksum error ................................................51
8.2.11.Error code 13 –Optical sensor dirty –cleaning required......................................51
8.2.12.Error code 14 - Supply pressure not within permissible range..............................51
9. Maintenance and repair .......................................................................................52
9.1. Maintenance........................................................................................................52
9.1.1. Maintenance cycles for reliable operation............................................................52
9.1.2. Maintenance by operator .....................................................................................54
9.1.3. Maintenance by Schaller service partner .............................................................54
9.1.4. Cleaning the light path (4.000 h)..........................................................................54
9.1.5. Filter des Druckreglers austauschen....................................................................56
9.1.6. Replace connection box seal...............................................................................57
9.1.7. Kompletten Ölnebeldetektor überholen................................................................61
10. Repair..................................................................................................................61
10.1. Repair by the operator.........................................................................................61

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
10.1.1.Replacing the measuring head.............................................................................61
10.1.2.Replacing the battery...........................................................................................64
10.1.3.Replacing the terminal box...................................................................................69
10.1.4.Replacing the pressure regulator.........................................................................74
10.1.5.Replacing connecting hose..................................................................................76
10.1.6.Replacing seal of inspection cover.......................................................................77
10.1.7.Replacing seal for mounting plate........................................................................79
10.1.8.Replacing the screw plus.....................................................................................82
10.2. Repair by Schaller Automation.............................................................................83
10.3. Decommissioning and disassembling ..................................................................83
11. Storage................................................................................................................83
12. Packaging............................................................................................................83
13. Spare parts..........................................................................................................84
13.1. Spare parts list VN2020......................................................................................84
13.2. Spare parts list VN2020 Ex..................................................................................85
13.3. Maintenance kit (4.000 h / 6 Months)...................................................................86
13.4. Cleaning kit (4.000 h)...........................................................................................86
13.5. Service kit for VN2020 (16.000 h / 24 Monate).....................................................87
13.6. Accessories VN2020 / VN2020 Ex.......................................................................88
14. List of figures .......................................................................................................89
15. Contact................................................................................................................93
16. Modification log....................................................................................................94
Index
Index
Change
Date
Changed by
1.0
Release
19.12.2019
Adams, P. / Höh, S.
1.1
See modification log
13.03.2020
Adams, P. / Höh, S.

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
1. Technical data and scope of delivery

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
Mechanical interfaces
Dimensions
Approx. 543 x 298 x 171 mm
Weight
12.41 kg
M1
External thread M16x1.5
Pipe connection, Ø10
M2
External thread M30x2
Pipe connection, Ø22
M3
External thread M30x2
Pipe connection, Ø22
M4
Internal thread G1/4
M5
4x through holes for screws M8
Electrical interfaces
Power supply
18 - 31.2 V DC
Nominal voltage
24 V DC
Current consumption
Maximum 2A
Supply E1
24 V DC
M25: Cable diameter 8-16mm
Grounding 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

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
Pneumatic interfaces
P1
External thread M16x1.5
Pipe connection, Ø10
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. -55mmWc (-5.5 mbar)
Nom. -60mmWc (-6 mbar)
Max. -65mmWc (-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

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
2. Identification
2.1. Product 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. The Manufacturer
Schaller Automation
Industrielle Automationstechnik GmbH & Co. KG
Industriering 14
66440 Blieskastel
Germany

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
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 pipes.
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.

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
4. Oil mist detection system
An oil mist detector 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 setups for a VN2020 installation kit for a six-cylinder
engine.
Figure 1: Oil mist detector system
(1) Oil mist detector
(2) Bracket
(3) Engine wall connection
(4) Pipe siphon
(5) Pipe support
(6) Suction line for connection box
(7) Header pipe
(8) Suction pipe
(9) Exhaust pipe
1
+
9
2
3
5
4
6
7
8

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
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) Protection cover
(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) Pressure regulator
(11) Terminal box
1
2
3
4
5
9
8
7
6
10
11

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
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
The oil mist detector complies with classification II (2G) [Ex op is IIB T4 Gb].

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
*The brackets indicate, that the device is installed outside the hazardous area () but emits optical radiation into an
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
information for 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
connections 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).
+5°≤+70°C
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 athmosphere (G=Gas)
Equipment Category (Category 2, High protection, one fault)
Equipment Group (II: non Mining)
EU Explosive Athmosphere Symbol

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
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 detector system (installation kit).

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
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
detector 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 engine room 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.

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
4.4. Engine wall connection and suction funnel
Eine Motorwandverschraubung besteht im wesentlichen aus zwei Hauptkomponenten, dem
Verschraubungskörper (1) und einem sogenannten Ansaugtrichter (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. Splash oil can clog the header pipes if
it is not properly separated beforehand.
The fitting body allows for angular adjustment to accommodate the suction pipes and forms the
connection between the header pipes, suction pipes and the crankcase.
Schaller Automation offers engine wall connectionc in various versions and specifically
depending on the engine peripherals.
4.5. Siphon blocks
The blocks are the alternative to the engine wall connections. They are used where a drainage
concept using pipe siphons is not possible because of the nature of the peripherals.
1
2

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
4.6. Hoses
Hoses can also be used as an alternative to the suction and exhaust pipes.
The hoses used by Schaller Automation consist of a hydraulic hose with an additional coating of
galvanised wire mesh.
Figure 8: Hoses with wire mesh
The hoses 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. Pipe siphon
During the suction process for an atmosphere containing oil mist, oil may settle in the suction
pipes.
The pipe siphon has the task of draining this settled oil in the header pipes before it clogs or
constricts the pipes.
Figure 9: Pipe siphon
At least two pipe siphons are therefore required per installation kit.

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
www.schaller-automation.com
4.8. Optional accessories
4.8.1. Remote monitoring systems
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 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.

Operation manual VISATRON VN2020 V1.1 03/2020 EN
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SCHALLER AUTOMATION 66440 Blieskastel / Saarland / Deutschland / Industriering 14 / Postfach 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. [phone]/ Fax -260 / eMail: [e-mail] /
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!