Version 2.

2, 05/2009

VISATRON®
Oil Mist Detectors
VN115/93
VN116/93
VN215/93
Operation Manual
Part-No. 10980

IACS UR M67 type approved

Operation Manual VISATRON® series VN93 05/2009
Page 2

About this Manual

This manual was designed to answer your questions concerning the handling,
operation and maintenance of the Oil Mist Detector (OMD) VISATRON® series
VN93.

The operating instructions are applicable for:

VN115/93
VN116/93
VN215/93

Should you encounter any interruption or breakdown of your VISATRON® series

OMD device during operation, please contact your local representative (refer to
chapter 10 ‘Service Partners’) or SCHALLER AUTOMATION Industrielle
Automationstechnik GmbH & Co. KG directly. The repair of OMD devices may only
be carried out by authorized repair centres. You can expect safe and reliable
operation of your OMD only when the device is operated in accordance with this
manual.

Please take note of the following:

x Please read this manual thoroughly and acquaint yourself with the correct
installation, operation and maintenance of your VISATRON® series VN93 device.
x Installations of the VISATRON® series VN93 devices have to be in accordance to
the IACS UR M10 if applicable.
x Use the VISATRON® series VN93 devices only for the purpose described in the
operation manual.
x Incorrect maintenance and handling errors may cause possible device failure or
an unsafe operating environment.
x The VISATRON® series VN93 devices may only be used by authorised staff.
x This operation manual must be available at the place of installation at all times.

Terms and conditions of sale

The standard terms and conditions of sale of SCHALLER AUTOMATION shall apply to
all VISATRON® and related products.

SCHALLER AUTOMATION Industrielle Automationstechnik GmbH & Co. KG warrants

that under proper use, handling and maintenance OMD VISATRON® series VN93 is
free from defects in material, design and/or workmanship. Claims of
buyers/operators, in particular compensation fro damage, which does not arise at
OMD VISATRON® series VN93 itself or for natural wear and tear of consumable
supplies, e.g. filters etc., are excluded. SCHALLER AUTOMATION Industrielle
Automationstechnik GmbH & Co. KG is not responsible for defects which arise as a
result of:

a) natural wear and tear, improper commissioning, improper use/handling, use of

unsuitable power supply, welding processes on the engine as well as non-

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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observance of commissioning, installation, operating and service instructions as

given in this Operation Manual
b) components and design other than the OMD VISATRON® series VN93
c) alterations or modifications of the OMD VISATRON® series VN93 carried out by
the buyer/operator or third parties without written authorization of SCHALLER
AUTOMATION Industrielle Automationstechnik GmbH & Co. KG
d) incorrect combination of devices and/or components or operation of devices
and/or components which are not certified to be compatible or not permitted by
the manufacturer - SCHALLER AUTOMATION Industrielle Automationstechnik
GmbH & Co. KG

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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Safety instructions

The series VN93 devices are manufactured according to the high quality standards
of SCHALLER AUTOMATION and must pass stringent factory tests. In order to keep
the device operating reliable and trouble free, the user has to take note of the
safety hints and warnings. In the instruction manual they are marked with the
following symbols.

Used symbols

CAUTION! Do not ignore the text in this box. Personell safety

can be endangered or the device can be damaged.

WARNING! This text contains important information.

The marked text contains only a hint for faster processing.

CAUTION! Unplug the OMD during welding processes

on the engine.

Reset of Oil Mist Alarms

CAUTION!
Ensure, that the oil mist concentration inside the
engine has fallen under the Lower Explosion Level
(LEL) before acknowledging an oil mist alarm by
pressing the Oil-Mist-Alarm button. Otherwise you
risk an oil mist explosion!

Follow the instructions of the engine builder, ship

yard and ship owner.

Use a monitoring device at a safe location to read off

the current oil mist concentration. SAB recommends
to wait until more than the half of the indication
LED’s are switched off (VISATRON®-device and
Remote Indicator II) or the oil mist alarm level has
to reduce below 50% (ReCon DS23).

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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Declaration of Conformity

We, the manufacturer

SCHALLER AUTOMATION
Industrielle Automationstechnik GmbH & Co. KG
Industriering 14
D-66440 Blieskastel
Germany
Tel.: 06842 / 508-0
Fax: 06842 / 508-260

declare on our own responsibility, that the product:

Kind of equipment: Oil Mist Detector

Type-designation: VISATRON® VN115/93

VISATRON® VN116/93
VISATRON® VN215/93

is in compliance with following standards :

EN 61000-4-2
EN 61000-4-3
EN 61000-4-4
EN 61000-4-5
EN 61000-4-6
CISPR 16-1
CISPR 16-2
IACS UR M67

D-66440 Blieskastel, 2007/07/25

Stephan Schaller
- Managing Director -

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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Table of Contents

1 Introduction and functional overview ...............................8

2 Installation instructions ..................................................12
2.1 Mechanical installation ........................................................ 12
2.1.1 Basics................................................................................12
2.1.2 Pipe dimensions ..................................................................16
2.1.3 Installation of pipe siphons ...................................................17
2.1.4 Installation of the siphon block connection units ......................19
2.1.5 Suction funnels in the crankcase compartment ........................20
2.1.6 Pipe arrangement at valve box (VN215/93 system only) ...........21
2.1.7 Compressed air connection ...................................................22
2.2 Electrical installation ........................................................... 23
2.2.1 VISATRON® series VN93 device ............................................23
2.2.2 Connection of monitoring devices ..........................................26
2.2.3 Schematic electrical wiring diagram .......................................28
3 Commissioning ................................................................29
3.1 Adjusting or checking the suction pressure ......................... 29
3.2 Filling of siphon blocks VN280plus of VN215/93 system with
oil ........................................................................................ 30
3.3 Filling of siphon blocks VN180 for VN115/93 and VN116/93
system with oil .................................................................... 32
3.4 Filling of pipe siphons for VN115/93 and VN116/93 system
with oil ................................................................................ 33
3.5 Adjusting the sensitivity of the OMD.................................... 34
3.6 Commissioning check list..................................................... 35
4 Operating instructions.....................................................36
4.1 Display................................................................................. 36
4.2 Parameter Adjustment......................................................... 38
4.3 Diagnostics .......................................................................... 39
4.4 Reset of Oil Mist Alarms....................................................... 41
5 Troubleshooting ..............................................................42
5.1 Clean scavenging air bores .................................................. 43
5.2 Clean infrared filter.............................................................. 43

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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5.3 Exchange air filters in the measuring head .......................... 44

5.4 Exchange air filter in pressure regulator unit ...................... 44
5.5 Exchange measuring head ................................................... 45
5.6 Measuring head fuses .......................................................... 46
6 Maintenance procedures .................................................47
7 Functional test ................................................................48
7.1 On board test ....................................................................... 48
7.2 Factory test at engine builder with smoke generator on
VN115/93 and VN116/93 installations................................ 50
7.3 Additional pressure measurement on VN115/93 and
VN116/93 installations........................................................ 51
7.4 Factory test at engine builder with fog machine on VN215/93
installations ......................................................................... 53
8 Spare Parts and Accessories............................................55
9 Technical data .................................................................61
10 Service Partners ..............................................................66

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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1 Introduction and functional overview

The VISATRON® series VN93 Oil Mist Detector (OMD) from SCHALLER
AUTOMATION protects large diesel engines against oil mist explosion caused by
spontaneously occurring oil mist. It is part of a safety system that helps protect
operating personnel and prevents heavy damages to the engine.

This device conforms to the IACS UR M10 which is valid since January 2006.

It is not possible to directly monitor all potential sources of oil mist inside a large
diesel engine. There are main bearings, large end bearings, pistons, liners, sliders,
pumps, camshaft bearings, chains, gears or even tools left behind from installation
– all of these parts could produce oil mist e.g. in case of lubrication problems.
Therefore the philosophy of SCHALLER AUTOMATION is that only OMD-systems can
securely prevent oil mist explosions by detecting the primary origin of danger: the
oil mist itself.

The VISATRON® series VN93 OMD-system uses the approved wear-free suction
system to continuously extract the atmosphere of the crankcase compartments and
other engine locations. The system works actively and is not waiting for oil mist
clouds. This ensures proper reaction times from the beginning of oil mist generation
to an oil mist alarm.

To avoid false alarms caused by splash oil the suction system makes use of
Schaller's special suction funnels working independent of the rotation sense of the
engine. Additional draining components ensure correct working under all operating
conditions. This includes the application in power plants as well as on vessels with
their static or dynamic inclinations. False alarms initiated by condensing water
vapour are prevented by an integrated heater inside the measuring head housing.

The OMD-system consists of following parts:

x VISATRON® series VN93 oil mist detector

x Protection cover
x Suction system including pressure regulator
x Monitoring device

Three different types of the VISATRON® series VN93 oil mist detectors are
available (see Figure 1):

x VN115/93
x VN116/93
x VN215/93

All devices have a measuring head (2) which includes the optical measuring track
under the control cover (3), a label on the front side and a display to give the user
all important information for normal operations conditions. The measuring head is
mounted on a vibration protected base plate.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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The negative pressure for the suction system is generated by an air jet pump (1)
working with the Venturi principle. The electrical interface is integrated within a
socket housing (5). The device can be connected directly to the engine safety
system. The interface includes two Oil-Mist-Alarm outputs, a Pre-Alarm output and
a Ready signal.

VN115/93 VN116/93 VN215/93

Figure 1: Types of VISATRON® series VN93

VN115/93
The suction system is connected to the common "Connecting Box" (4). This type of
oil mist detector is able to detect an oil mist alarm, without identifying the location
of the oil mist source inside the engine.

VN116/93
The suction system is connected to the "Valve Box 116" (4). This type of oil mist
detector is able to detect an oil mist alarm, indicating in the valve box window the
left or right side of the detector with the highest oil mist concentration.

VN215/93
The suction system is connected to the "Valve Box 215" (6). This type of oil mist
detector is able to detect an oil mist alarm, indicating in the valve box window the
compartment with the highest oil mist concentration.

In normal operation mode all models sample the atmosphere of the engine at all
suction points in parallel through the suction system to the measuring head. Upon
detection of an oil mist alarm the models VN116 and VN215 start an additional
search run to determine the location of the highest oil mist concentration. The
reaction time to an alarm is totally independent of the search run.

The devices offer two alarm levels: Main-Alarm and Pre-Alarm. They can be
adjusted by the light buttons (see chapter 4).

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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To keep the optical track clean all models use clean scavenging air in front of the
filter glasses. This air is derived from the compressed air driving the air jet pump.

The devices can be ordered as single OMD device or integrated in a mounting unit.
In this case the scope of supply includes an additional pressure reducer and a
protection cover.

Protection cover

Pressure
regulator unit

Figure 2: VISATRON® VN215/93 oil mist detector with protection cover and
pressure regulator unit

The suction system always requires a so called 'suction funnel' at each suction
point. This prevents the system against incoming splash oil. During normal
operation mode of an engine the OMD sucks out a small concentration of oil mist
which was generated by blow-by or mechanical spraying. This oil mist intercepts in
the suction pipes and must be drained back to the crankcase.

Figure 3:
siphon block VN180 siphon block VN280plus pipe siphon

The best method on a VN115/93 and VN116/93 installation to drain the system is
to use pipe siphons. Also recommended is the use of siphon blocks.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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On 2-stroke engines the crankcase and the combustion chambers are separated by
stuffing boxes, which let the crankcase be nearly free of blow-by. Therefore it's also
possible to use the suction funnel as a draining device. In this case it is necessary
to mount the suction pipes with an inclination of greater than 6°.

To become independent from fast changes of the engine room air pressure, it is
recommended that the output of the air jet pump is blown back into the crankcase.
If the air is blown into the engine room, SCHALLER AUTOMATION offers an optional
oil separator which should be mounted directly to the output of the pump.

Figure 4: Oil separator for air outlet

The OMD device can be connected to Schaller's monitoring devices Remote

Indicator II or ReCon DS23 to monitor the oil mist concentration and the status of
the OMD device from a safe location as requested by IACS UR M10. The connection
to the monitoring devices is realized by a RS485 two-wire bus. Additionally Schaller
realized an integration of the VISATRON® devices into ship automation systems
(e.g. Mega-Guard of Praxis).

Figure 5: Remote Indicator II Figure 6: ReCon DS23

Thus, the series VN93 is a further contribution to safety at sea. Our goal is to avert
damage to assets, personnel and the environment.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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2 Installation instructions

2.1 Mechanical installation

2.1.1 Basics
There are multiple potential sources of oil mist inside an engine. These are for
example defective main bearings, connecting rod bearings as well as piston
seizures, chains and covers of pumps. For each of these individual sources you
could determine the "optimum" suction point. The result would be a vast number of
holes to be distributed over the entire engine. To find out a safe and economic
solution to monitor oil mist SCHALLER AUTOMATION recommends the OMDEA-test
(Oil Mist Detection Efficiency Approval). In each case the following rules are
recommended.

CAUTION! Do not ignore the guidelines. The safety of

persons can be endangered

Following rules are recommended by SCHALLER AUTOMATION:

x Use at least one suction point per compartment.

x Use always the long version of the suction funnels. This makes the
installation independent from the rotation sense of the engine.
x At least one suction point per chain drive or gear drive is necessary.
x Avoid the splash oil disk of the crankshaft bearings.
x Select points in the upper area of the crankcase, as oil mist tends to rise
upwards!
x The detection unit has to be placed above the suction points.
x Installation Rules: in general avoid U-bends or kinks in the tubing system.
o VN115/116 with pipe siphons: Mount one pipe siphon at each end of
the horizontal header pipes, place the pipes a little bit above the
suction points and connect the pipes and the engine wall connections
with flexible tubes.
o VN115/116 with siphon blocks: Use one siphon block at each
compartment.
o VN215 with siphon block: Use one siphon per compartment. If a
suction point is placed above the detection unit e.g. at the camshaft
use a pipe siphon at the lowest point of the pipe to avoid an oil pocket,
which could clog the pipe.
o VN215 without draining components: The pipes have to be mounted
with an angle greater than 6° inclination.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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x If possible mount the device on the engine side opposite to the crankcase
relief valves to reduce danger to the crew during a damage situation.
x If possible place the VISATRON® detection unit in the center of the engine to
avoid long pipe runs.
x Select only suction points which allow the use of long suction funnels. In this
case the installation side is independent from the rotation sense of the
engine. Installations without any suction funnels are not allowed.
x If recommended by engine builder, determine an additional suction point at
the camshaft bed.
SCHALLER AUTOMATION recommends a final test procedure per engine
type called OMDEA (Oil Mist Detection Efficiency Approval).

According to the IACS unified requirement M10 the installation drawings have to be
approved from engine builder and SCHALLER AUTOMATION. The installations have
to be executed in compliance with these drawings and the contents of this manual.

The following figures show typical installation arrangement on a 6 cylinder engine.

Figure 7: Recommendation for best VN115/93 OMD installation

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 14

Figure 8: Alternative installation of VN115/93 OMD

Example of an VISATRON VN116/93 installation on a 6-cyl. engine with

engine wall connections (oil draining through pipe siphons)

recommended:
manoeuvre
side
suction point

engine wall
connection

flexible hose
exhaust
engine wall engine wall engine wall engine wall
pipe connection connection connection connection
pipe
siphon siphon
additional suction points, e.g.:
chain/gear-case
thrust bearing

compartment 1 compartment 2 compartment 3 compartment 4 compartment 5 compartment 6

Figure 9: Recommendation for best VN116/93 OMD installation

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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Example of an VISATRON VN116/93 installation on a 6-cyl. engine with

siphon blocks (oil draining through siphon blocks)

recommended:
manoeuvre
side
suction point

engine wall
exhaust connection

siphon- siphon- siphon- siphon- siphon- siphon-

block block block block block block
VN180 VN180 VN180 VN180 VN180 VN180

additional suction points, e.g.:

chain/gear-case
thrust bearing
compartment 1 compartment 2 compartment 3 compartment 4 compartment 5 compartment 6

Figure 10: Alternative installation of VN116/93 OMD

Figure 11: Recommendation for best VN215/93 OMD installation

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 16

Figure 12: Alternative installation of VN215/93 OMD

2.1.2 Pipe dimensions

x For VN115 and VN116 standard applications:

o Seamless steel Pipes: 22 mm outer diameter, 2 mm wall thickness
o Flexible hoses: inner diameter not less than 6 mm

x For VN215 standard applications:

o Seamless steel pipes: 14 mm outer diameter, 2 mm wall thickness
or, if 14 mm is not available
o Seamless steel pipes: 13,71 mm (known as1 /4-inch pipes, schedule
no. 40, 0.540 inch outer diameter, 0.088 inch wall thickness)

The length of the exhaust air pipe (outlet of the venturi injector) is restricted to
max. 2m. The inner diameter has to be • 18 mm. U-bends and kinks are forbidden.

Other installation solutions must have written agreements by SCHALLER

AUTOMATION as required by IACS UR M10.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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2.1.3 Installation of pipe siphons

Figure 13: Pipe siphon

x Mount the engine wall connection into the G3/4" thread with 110 Nm torque
x Put the pipe siphon in the hole
x Fix the clamping nut
x Fill the pipe siphon with oil (see chapter 'commissioning')
x Fix the flexible tube on the top fitting

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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x
Figure 14: Pipe siphon at engine wall Figure 15: Image of pipe siphon

Crank case atmosphere

Header pipe
Flexible hose to
suction point
Oil

Flexible hose
to pipe siphon

Figure 16: Oil draining principle

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 19

2.1.4 Installation of the siphon block connection units

Figure 17: Connection unit

Consider the following points:

x Take note of the drilling template (made of paper, included with the
connection units)
x Drill through
x Seal all threads with 'Loctite 572'
x Max. torque = 30 Nm

OKAY Wrong alignment Wrong angles Wrong distance

Figure 18: Side view

x Avoid wrong alignment, wrong angles and incorrect distances (see Figure 18)

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
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x Insert the suction funnel from the crankcase side into the siphon block, align
it in a vertical position (see Figure 19) with the opening at the bottom
and fix the small clamping nut.

2.1.5 Suction funnels in the crankcase compartment

The suction funnels have to be fitted in such a way that flooding by splashing
bearing oil or returning piston cooling oil is avoided (see Figure 19).

CAUTION! Make sure funnels do not interfere with rotating or

moving parts of the engine.

Figure 19: Different types of suction funnels

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 21

2.1.6 Pipe arrangement at valve box (VN215/93 system only)

or

or

Figure 20: Pipe arrangement for 4 to 8 suction points

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 22

or

Figure 21: Pipe arrangement for 9 and 10 suction points

CAUTION! Other arrangements are not valid. Unused

connection points (see Figure 20 and Figure 21, marked dark
grey) have to be closed by supplied rubber plugs.

2.1.7 Compressed air connection

If the SAB pressure regulator (see Figure 22) is used connect the compressed air
supply at the NTP/BSP/G1/4A fitting. Use only dry and clean compressed air within
a range of 2 - 15bar.

Fine pressure
regulator Throttle block

Air inlet

Air outlet
Air filter

Figure 22: SAB pressure regulator unit

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 23

2.2 Electrical installation

2.2.1 VISATRON® series VN93 device

The electrical terminal is inside the socket housing (see Figure 23) on the base
plate of the VISATRON® device. The pin assignment is specified in Figure 26. The
cable entry points are located on either side.

Fixing screws
of terminal

Cable entry
Cable entry

Figure 23: Socket housing

According to the pin assignment of Figure 26 connect the VISATRON® device to the
24 Volts power supply. The supply voltage can be potential free or not. The earth
connection between the OMD and the engine is carried out by the fixing screws of
the base plate or protection cover.

Additionally connect one alarm relay output to the safety system of the engine. As
specified by the classification societies the 'Alarm' relay must be connected either to
the shutdown or to the slow-down input.

During normal operation the alarm relay is switched off. In case of an oil mist alarm
the relay is switched on. To monitor this output, a wire break resistor is installed
(between pin 7 and 8 and between 15 and 16 as shown in Figure 26).

To replace the wire break resistors the measuring head has to be dismounted. The
resistors (see Figure 25) are located on the rear side under the plastic cover (see
Figure 24). The plastic cover can be removed via the screws. Do not forget to write
the resistor value on the plastic cover with a permanent marker.

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Operation Manual VISATRON® series VN93 05/2009
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Plastic cover

Fixing screws of
plastic cover

Figure 24: Rear side of measuring head

The second 'Alarm' output must be connected to separate channels on the alarm
monitoring system of the vessel or power plant and the 'Ready' output. The 'Ready'
relay is switched on when the OMD is in correct operation (see Figure 26).

Wire break resistors

Figure 25: Wire break resistors

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Operation Manual VISATRON® series VN93 05/2009
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The optional pre-alarm output can be used to initiate either a pre-warning signal or
slow-down signal. The pre-alarm relay is switched on when the oil mist
concentration has risen to the adjusted level. Depending on the characteristics of
an oil mist occurrence the time between 'Pre-alarm' and 'Alarm' could be only a
fraction of a second.

Description Pin Description

24 Volts DC 1 9 'Pre-alarm' relay
24 Volts DC GND 2 10 'Pre-alarm' relay
'Ready' relay closed 3 11 RS485 B
'Ready' relay open 4 12 Reserved, do not use
'Ready' relay common 5 13 RS485 A
'Alarm' 1 relay closed 6 14 'Alarm' 2 relay closed
'Alarm' 1 relay open 7 15 'Alarm' 2 relay open
'Alarm' 1 relay common 8 16 'Alarm' 2 relay common

Figure 26: Pin assignment

We recommend to connect 'Alarm' 1 to the alarm system and 'Alarm' 2 to the

safety system.

The relay outputs are potential-free.

Power supply 18 – 31.2 Volts DC, max. 3 A

Nominal voltage 24 Volts DC
Relay Outputs Max. 60 Volts DC/AC, 60W, 125VA, 2A
Internal fuse 3.15 A semi time lag

Table 1: Electrical specification

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Operation Manual VISATRON® series VN93 05/2009
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2.2.2 Connection of monitoring devices

As required by IACS UR M10 the OMD device can be connected to Schaller's remote
monitoring devices Remote Indicator II or ReCon DS23 to monitor the oil mist
concentration and the OMD status from a safe location.

The connection to the monitoring devices is accomplished via a RS485 two-wire

bus. In case of a Remote Indicator II or a standard ReCon DS23 installation the
connection is only a two point link. The bus system at the OMD device must be
terminated by the resistor. It is integrated in the terminator (see Figure 27), which
is supplied with the monitoring device.

The used communication cable must be twisted pair and shielded. We recommend
LAPPKABEL UNITRONIC-FD CP (TP) plus UL-CSA, AWG20. The total bus length is
limited to 400 m. The VISATRON® device cable entry (see Figure 27) at the
VISATRON device is designed for cable diameter between 7.5 and 10.0 mm.

Figure 27: Cable entry and bus-terminator on the bottom side of the VISATRON®
device

The connection between the OMD device and the monitoring device for standard
applications is shown in the following wiring diagram (see Figure 28). If more than
one OMD device is connected to a ReCon DS23 unit follow the installation
instructions in the ReCon DS23 manual.

WARNING! The shield must be connected directly at the

cable grommet.

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Operation Manual VISATRON® series VN93 05/2009
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Monitoring device

Terminator

13 11 2 1

ł ł ł ł

Figure 28: Wiring diagram to connect Remote Indicator II or ReCon DS23

WARNING! Install only 1 terminator at the end of the bus

system if multiple VISATRON® VN93 devices are connected
to 1 ReCon DS23 unit.

The monitoring device is the bus master and the OMD devices are the slaves. It is
necessary to adjust different bus addresses at each slave device. Normally the first
OMD device gets the address '1' and so on. The address can be adjusted by the
light buttons (see chapter 4).

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 Operation Manual VISATRON® series VN93 05/2009
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2.2.3 Schematic electrical wiring diagram

Engine room

VN93

Ready and alarm signals

Engine control room

Engine safety system

Optional 4 – 20 mA

RS485 2-wire-bus

Remote Indicator II

Alarm monitoring system

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Operation Manual VISATRON® series VN93 05/2009
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3 Commissioning

CAUTION! Unplug the OMD during welding processes

on the engine.

3.1 Adjusting or checking the suction pressure

The suction pressure must be set by adjusting the pressure regulator when the
engine is at standstill. Make sure ventilation of the engine room is in operation.

Setscrew

Counter-nut

Figure 29: Pressure regulator unit

WARNING! Adjust 60 mm WC negative pressure.

After adjustment, remove U-tube pressure gauge and screw
in the previously removed plug.

CAUTION! A pressure setting much higher than 60 mm WC

negative pressure may cause a change in detecting
sensitivity and can impact the functionality of the siphon
blocks.

x Connect a U-tube manometer at inspection cover (see Figure 30).

(U-tube manometer is included in the service box, available as an option).
x Switch on compressed air supply with inlet pressure in a range from 2 to 15
bar (before connecting the OMD the first time check the pressure).
x If the negative suction pressure is already adjusted to 60 mm WC within a
tolerance of ±5 mm remove the U-tube manometer and finish the procedure.
x Otherwise loosen counter-nut.
x Turn setscrew until the negative pressure is only 60 mm WC.
x Tighten counter-nut.

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Operation Manual VISATRON® series VN93 05/2009
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Figure 30: U-tube manometer connected to OMD control cover

x Remove U-tube manometer

3.2 Filling of siphon blocks VN280plus of VN215/93 system with oil

x Press the pump lever of the filling pump (see Figure 32) as many times until
the first oil drops come out.
x Unscrew the lower siphon block plug (see Figure 31).
x Insert filling pump nozzle.

Figure 31: Siphon block VN280plus

Figure 32: Filling pump

x Press the black nipple into the opening of the block.

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Operation Manual VISATRON® series VN93 05/2009
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x Push the nozzle to the first mark (see Figure 33).

Marks

Figure 33: Marks on the nozzle

x Fill the first siphon with 12 pump strokes, push the nozzle to the next mark
and repeat the procedure until the nozzle reaches the rear plate.

CAUTION! Do not fill with more than 12 strokes per

siphon. The excess oil may flow in the suction tubes.
Additionally the excess oil can remove the required oil in the
siphon by a physical suction effect through the draining
channel.

The number n of internal siphons is equal to the number of

pipe connections. This means, that the pump has to be used
n times at varying positions.

x Close the threaded hole with the plug (a small amount of oil coming out does
not impact the functionality.
x Clean the siphon block.
x Continue with the next block.

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Operation Manual VISATRON® series VN93 05/2009
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3.3 Filling of siphon blocks VN180 for VN115/93 and VN116/93 system
with oil

x Press the pump lever of the filling pump (see Figure 35) as many times until
first oil drops are coming out.
x Unscrew the lower siphon block plug (see Figure 34).
x Insert filling pump nozzle (see Figure 36).

Oil input

Figure 34: Siphon block VN180

Fitting

Lock nut

Figure 35: Filling pump

x Screw in the fitting of the filling pump.

x Press the nozzle to stop position.
x Tighten the lock nut.
x Fill the siphon with 8 strokes.

CAUTION! Do not fill with more than 8 strokes. The excess

oil may flow in the suction tubes. Additionally the excess oil
can remove the required oil in the siphon by a physical
suction effect through the draining channel.

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Operation Manual VISATRON® series VN93 05/2009
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Figure 36: Filling pump inserted and fixed in the siphon block

x Remove the filling pump.

x Close the threaded hole with the plug (a small amount oil coming out does
not impact the functionality.
x Clean the siphon block.
x Continue with the next block.

3.4 Filling of pipe siphons for VN115/93 and VN116/93 system with oil

Fitting to
flexible hose
and oil input

Figure 37: Pipe siphon

x Remove flexible hose

x Fill in 70ml lubrication oil
x Fix flexible hose again

CAUTION! Do not fill in more than 70ml, the excess oil can
remove the required oil in the siphon by a physical suction
effect through the draining channel.

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Operation Manual VISATRON® series VN93 05/2009
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3.5 Adjusting the sensitivity of the OMD

The detector determines the oil mist concentration by an optical measurement. The
calculated values have the unit 'opacity'. 100% opacity means that no light is
transmitted through the oil mist sample. This is equivalent to a complete white
wall.

The IACS UR 67 requires an oil mist alarm at 5% of the Lower Explosion Level
(LEL). The LEL is equal to 47mg/l oil mist concentration in air at a temperature of
25 °C, which means that the OMD is required to indicate an oil mist alarm at
approx. 2.5mg/l.

Position VN115 alarm level in VN116/VN215 alarm level in

opacity opacity
3 1.5% 1.6%
4 2.0% 2.4%
5 3.0% 3.7%
6 5.0% 5.5%

Table 2: Sensitivity switch position and corresponding oil mist alarm level

Inside the measuring head 2.5mg/l oil mist concentration is approx. 23% absolute
opacity compared to the full measuring range.

The number of suction points, the different oil mist concentration in the
compartments and the progress of oil mist occurrence can influence the amount of
oil mist being sucked out of the engine to the measuring head. Therefore the
amount of oil mist concentration to be detected is variable. The use of the alarm
levels 3 and 4 is in accordance to the unified requirements M67.

CAUTION! Use only level 3 or 4 for normal diesel engines.

Level 5 and 6 must be confirmed in writing by SCHALLER
AUTOMATION.

The sensitivity of the VISATRON® oil mist detector can be adjusted by the light
buttons (see chapter 4).

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Operation Manual VISATRON® series VN93 05/2009
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3.6 Commissioning check list

Mechanical check
Are all suction pipes installed as specified in the installation Ŀ yes / Ŀ no
drawing?
Are all fittings fastened and tight? Ŀ yes / Ŀ no
On VN215/93 installation: Is the arrangement of the pipes at Ŀ yes / Ŀ no
the valve box correct?
On VN215/93 installation: Are all un-used openings at the valve Ŀ yes / Ŀ no
box closed?
On installations with siphon blocks: Are all siphon blocks filled Ŀ yes / Ŀ no
with oil and all un-used openings closed?
On installations with pipe siphon: Are all siphons filled with oil? Ŀ yes / Ŀ no
On installations with oil separator: Is the separator filled with Ŀ yes / Ŀ no
oil?
Is the negative pressure at the measuring head adjusted to 60 Ŀ yes / Ŀ no
mmWC?
Adjusted negative pressure mmWC

Electrical check
Is the power supply connected to the terminal and is the Ŀ yes / Ŀ no
voltage within the specified range?
Measured supply voltage Volts
Is the monitoring device installed? Ŀ yes / Ŀ no
Are the ‘Alarm’ and ‘Ready’ signals connected to the engine Ŀ yes / Ŀ no
control and safety system?
Are the correct wire break resistors installed Ŀ yes / Ŀ no
Value of wire break resistor kOhm
Is the correct interface mode at pin 11 and 13 selected? Ŀ yes / Ŀ no

Functional check
On vessels perform the on-board test with test plate. Test Ŀ yes / Ŀ no
positive?
At engine factory perform smoke test. Test positive? Ŀ yes / Ŀ no
On VN115/93 installations, as an alternative to the smoke test, Ŀ yes / Ŀ no
measure the negative pressure at the end of the suction pipes.
Values as specified?

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Operation Manual VISATRON® series VN93 05/2009
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4 Operating instructions

4.1 Display
After power-on the VISATRON® device starts a 30 seconds count down before the
device enters the normal display mode. The device type appears in the upper ‘Code’
window and the current opacity in the ‘Value’ window. The ‘Ready’ LED indicates,
that the device is running well.

Light button: Up -116

0
Light button: Down

Light button: Reset/Enter

Figure 38: Normal display mode (VN116/93 as example)

The device offers a user interface to display and to adjust some parameters. Input
is performed via the three light buttons (see Figure 38). By touching the glass plate
the infrared light from the transmitter is reflected to the optical receiver which
generates a signal for the micro-controller.

-116
20

Blinking

Figure 39: Example of an oil mist alarm state with 20% opacity

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Operation Manual VISATRON® series VN93 05/2009
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In case of a high oil mist concentration the LED bar goes up. At 100% opacity,
compared to the alarm level, the 'Oil-Mist Alarm' LED starts blinking. If the opacity
later goes down, the alarm condition will be stored. The opacity is shown in the
right LED bar. If the highest LED is switched on the opacity is equal or higher,
compared to the alarm level.

By touching the light button ‘Up’ for longer than 3 seconds the ‘Parameter display
mode’ is activated. The available parameters are listed in Table 3. The ‘Up’ and
‘Down’ buttons can be used to navigate within this list.

If no button is touched for one minute the ‘Parameter display mode’ will be exited.

Code Description Unit/Format

-215/-116/-115 Opacity %
-001 Oil mist alarm level %
-002 Opacity relative to alarm level %
-003 Not used
-004 Not used
-005 Negative pressure inside measuring head % relating to
threshold
-006 Ambient temperature °C
-007 Electronic temperature °C
-008 Time hh.mm
-009 Date dd.mm
-010 Alarm level (see chapter 3.5)
-011 Oil mist pre-alarm level relative to the main %
alarm level (40 -100)
-012 Not used
-020 A/D converter: opacity
-021 A/D converter: air flow sensor
-022 A/D converter: ambient temperature
-023 A/D converter: electronic temperature
-024 For internal use
-025 For internal use
-026 For internal use
-027 Up-Counter s

Table 3: Parameters

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Operation Manual VISATRON® series VN93 05/2009
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4.2 Parameter Adjustment

By simultaneously touching the light buttons ‘Up’ and ‘Down’ for longer than 3
seconds the ‘Parameter adjustment mode’ is activated. The ‘Up’ and ‘Down’ buttons
can be used for navigation.

WARNING! The engine is not monitored In the ‘Parameter

adjustment mode’.

To enable the adjustment of all parameters, a password must be entered in

parameter P000 first, otherwise the parameters are only readable.

The value of the password is 4711 and cannot be changed. To input the password
first touch the ‘Enter’ button and then use the ‘Up’ and ‘Down’ buttons to scroll
through the numbers. Touch ‘Enter’ once again to input the currently indicated
number and move on to the next position.

To exit the ‘Parameter adjustment mode’ either simultaneously touch the light
buttons ‘Up’ and ‘Down’ for longer than 3 seconds or simply don’t press any button
for longer than one minute.

Code Description Range Factory Unit/

presetting Format
P001 Oil mist alarm level 3-6 4
P002 Used for service purpose, must
be always 0
P003 Used for service purpose, must
be always 0
P004 Oil mist pre-alarm level relative 40 - 100 100 %
to the main alarm level
P005 RS485 bus-address 1 - 16 1
P006 Restore presetting by enter ‘1’ 0 or 1 0
P050 Date 01.01 – dd.mm
31.12
P051 Date 1990 - yyyy
P052 Time 00.00 – hh.mm
23.59

Table 4: Adjustable Parameters

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Operation Manual VISATRON® series VN93 05/2009
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4.3 Diagnostics
If a device internal error or a system failure occurs the diagnostics system displays
the failure condition in the ‘Code’ window and the ‘Ready’ LED is off. The error
codes are shown in Table 5.

Error Codes Value Series VN93 device failures

E018 Voltage of internal battery too low
E017 Electronic module defective
E016 Electronic module defective
E015 % of max. Optical sensor very dirty
E014 % of switch-on Negative pressure/airflow too low
threshold
E013 % of max. Optical sensor dirty
E012 Checksum error
E011 Temperature Ambient temperature too low (<0°C)
E010 Temperature Ambient temperature too high (>70°C)
E009 Temperature Electronics temperature too low (<0°C)
E008 Temperature Electronics temperature too high (>75°C)
E007 Light button defective
E006 Voltage Supply voltage too high
E005 Not used
E004 Digital value Optical sensor defective
E003 Digital value Airflow-sensor defective
E002 Digital value Airflow-sensor defective

Table 5: Error codes

A detected oil mist alarm is displayed at this time with the 'Test' LED. In this case
the alarm relay or shutdown relay is not switched on.

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Operation Manual VISATRON® series VN93 05/2009
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E014
0

Figure 40: Device not ready, example of 'Negative pressure too low'

The second value shows the negative pressure in % relating to the switch-on
threshold.

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Operation Manual VISATRON® series VN93 05/2009
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4.4 Reset of Oil Mist Alarms

Caution!
Ensure that the oil mist concentration inside the
engine has fallen under the Lower Explosion Level
(LEL) before acknowledging an oil mist alarm by
pressing the Oil-Mist-Alarm button. Otherwise you risk
an oil mist explosion!

Follow the instructions of the engine builder, ship yard

and ship owner.

Use a monitoring device at a safe location to read off

the current oil mist concentration. SAB recommends to
wait until more than the half of the indication LED’s
are switched off (VISATRON®-device and Remote
Indicator II) or the oil mist alarm level has to reduce
below 50% (ReCon DS23).

The alarm condition can be reset only by pressing the Oil-Mist-Alarm reset light
button.

Figure 41: Oil-Mist-Alarm reset light button

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Operation Manual VISATRON® series VN93 05/2009
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5 Troubleshooting

Error Description Measure Chapter

18 Voltage of internal battery 1. Exchange measuring head 5.5 page 45
too low
17 Electronic module defective 1. Exchange measuring head 5.5 page 45
16 Electronic module defective 1. Exchange measuring head 5.5 page 45
15 Optical sensor dirty 1. Clean infrared filter 5.2 page 43
14 Negative pressure / airflow 1. Exchange air filters 5.3 page 44
too low 2. Clean fresh air bores 5.1 page 43
3. Check suction system
4. Adjust suction pressure 3.1 page 29
5. Adjust suction pressure 3.1 page 29
6. Exchange measuring head 5.5 page 45
13 Optical sensor dirty 1. Clean infrared filter 5.2 page 43
12 Checksum Error 1. Repeat parameter setting
11 Ambient temperature too 1. Remove ambient cooling
low (<0°C) components
10 Ambient temperature too 1. Remove or turn away ambient
high (>70°C) heating components
2. Install metal heat shields
against radiation
3. Install vortex coolers
9 Electronics temperature too 1. Remove ambient cooling
low (<0°C) components
8 Electronics temperature too 1. Remove or turn away ambient
high (>75°C) heating components
2. Install metal heat shields
against radiation
3. Install vortex coolers
7 Light button defective 1. Clean glass plate
2. Exchange Measuring head 5.5 page 45
6 Supply voltage too high 1. Measure supply voltage
2. Exchange measuring head 5.5 page 45
4 Optical sensor defective 1. Clean infrared filter 5.2 page 43
2. Exchange measuring head 5.5 page 45
3 Airflow-sensor defective 1. Exchange measuring head 5.5 page 45
2 Airflow-sensor defective 1. Exchange measuring head 5.5 page 45
All LED off 1. Measure supply voltage
2. Activate Self-repair of
Polyfuse 5.6 page 42
3. Replace measuring head fuse 5.6 page 42
4. Exchange measuring head 5.5 page 45

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Operation Manual VISATRON® series VN93 05/2009
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5.1 Clean scavenging air bores

Scavenging air
bore of left
chamber

Needle

Figure 42: Cleaning of scavenging air bore in the left and the right chambers

5.2 Clean infrared filter

CAUTION! Dirty optical filter glass may cause a loss of

sensitivity of the device.

IR-filter
Cleaning
glass
fluid

Cotton
stick

Figure 43: Cleaning of IR-Filter glass in the left and the right chamber

WARNING! Use only cleaning fluids for optical components as

delivered in the service box.

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Operation Manual VISATRON® series VN93 05/2009
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5.3 Exchange air filters in the measuring head

Scavenging
air filter left
chamber

Figure 44: Exchange of the air filters

WARNING! Do not try to clean the filters, use always new

ones.

5.4 Exchange air filter in pressure regulator unit

Lock screw

Figure 45: The air filter is behind the lock screw of the throttle block

WARNING! Switch off the compressed air supply during the

maintenance work. After the exchange re-check the negative
suction pressure.

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Operation Manual VISATRON® series VN93 05/2009
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5.5 Exchange measuring head

Additionally on
VN116 and VN215
Measuring head units:
main connector Valve box connector
Figure 46: Step 1 is to unplug the connectors

Fixing
screws

Figure 47: Step 2 is to unscrew the measuring head

To mount the new measuring head execute the 2 steps in reverse order.

WARNING! Check the values of the wire break resistors or in

case of doubt use the old ones.

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Operation Manual VISATRON® series VN93 05/2009
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5.6 Measuring head fuses

Fuse II

Figure 48 Fuse on the rear side of the measuring head

The device has two internal fuses. The first is located in the main connector of the
measuring head. This is a ‘self-repairing’ fuse which protects the filter circuit in the
connector.

To reset this fuse, unplug the main connector and wait 5 minutes before you plug
it again.

WARNING! Unplug the main connector during the exchange

of the fuse.

If all LED’s remain off exchange the 3.15 A semi lag fuse II at the rear side of the
measuring head (see Figure 48).

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 47

6 Maintenance procedures

CAUTION! Maintenance work has to be done when engine is

stopped.

Quarterly or after 2000 operating hours

1 Check negative pressure in the measuring head: See chapter 3.1
page 29
under 55 mmWC Æ adjust pressure
between 55 mmWC and 65 mmWC Æ okay
between 65 mmWC and 85 mmWC Æ adjust pressure
over 85 mmWC Æ check pressure regulator unit
2 Clean infrared filters in the measuring head See chapter 5.2
page 43
3 Clean fresh air bores in the measuring head See chapter 5.1
page 43
4 Exchange air filters in the measuring head See chapter 5.3
page 44
Half-yearly or after 4000 operating hours
5 Perform quarterly maintenance procedure 1 - 4
6 Exchange air filter in pressure regulator unit See chapter 5.4
page 44
Yearly or after 8000 operating hours
7 Perform half-yearly maintenance procedure 5 - 6
8 Clean suction system with compressed air. See chapter 3 page
ATTENTION, do not forget to refill the siphons! 29
9 Check the bellows and the suspension-system between
measuring head and base plate, check the scavenging
air outlet behind the control cover (see Figure 43) by
feeling the air stream to control scavenging air system
10 Perform functional test See chapter 7 page
48
Additional every 5 years
11 Exchange bellows Use services of our
partners (see
chapter 10)

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 48

7 Functional test

7.1 On board test

Attention: Before starting the on board test execute the

procedures as specified in the maintenance schedule. The
pipe system has to be clean and if used all siphons have to
be filled with oil (refer to chapter 2.1.3.)

Using the test plate set included in this manual folder, you can easily test the
functionality of the VISATRON® oil mist detectors and their connection to the
safety system of the engine. The set can also be ordered separately under Part.-No.
11072. It consists of the following parts:

A B
x Test plate (A)
x Test glass (B)
x Working instruction

Attention: You will stop or slow down the engine.

Test procedure step by step:

Step 1 Open the latches of the OMD control cover and

flip the cover to the left side.

Step 2 Press the test plate onto the openings.

Ensure that the openings are completely
covered. Now the device starts to create the
negative suction pressure again.

Step 3 Wait for the 'Ready'-LED on the display.

Step 4 Insert the test glass into the slot of the test
plate. The glass simulates oil mist and
generates an oil mist alarm.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 49

Step 5 Wait for the 'Alarm'-LED. At this comes on, the

engine has to stop or to enter the slow down
mode.
Step 6 Remove the test plate and put it together with
the test glass back into the bag.
Step 7 Close the control cover carefully.
Step 8 Wait for the 'Ready'-LED.
Step 9 Press the Oil-Mist-Alarm RESET button to
acknowledge the alarm state and enter the
normal monitoring mode.

If applicable perform an additional pressure measurement to check the tightness of

the suction system as described in chapter 7.3. Instead of an electronic gauge you
can use the U-pipe manometer of the service box.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 50

7.2 Factory test at engine builder with smoke generator on VN115/93

and VN116/93 installations

Both installation types can be verified by a smoke test. Due to vessels not normally
having the equipment SCHALLER AUTOMATION recommends this procedure only for
the factory test by using the SCHALLER smoke generator (see Figure 49). If a
smoke generator is available on a vessel this test can be also performed, however,
in this case observe the following warning.

Attention: Before starting the on board test execute the

procedures as specified in the maintenance schedule. The
pipe system has to be clean and if used all siphons have to
be filled with oil (refer to chapter 2.1.3.)

A complete test including the suction funnels can be done only at standstill of the
engine. The crankcase service covers must be opened first. Put a small amount of
smoke fluid (see Chapter 'Accessories') into the reservoir and switch on the
generator for a few seconds until the storage tank is completely filled with smoke.
This is important so that the tank can provide sufficient smoke to complete the
search run of a VN116/93 installation to determine the correct engine side. The last
step is to hold the flexible hose directly into the suction funnels until an oil mist
alarm is indicated.

Storage tank

Reservoir
Flexible hose

Figure 49: SCHALLER AUTOMATION smoke generator, see 'Accessories'

If it's not possible to open the service covers a functional test can be preformed
without testing the suction funnels.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 51

In this case the flexible hose has to be pressed over the opening under the lock
screws of the siphon blocks as seen in Figure 50 or has to be pressed over the open
header pipe end after removing the lock nut.

Lock screws

Figure 50: Test inlet on the siphon blocks VN180

Attention: In case of siphon block VN180 installation you

have to test all compartments and the additional suction
points at running engine.

7.3 Additional pressure measurement on VN115/93 and VN116/93

installations

Perform the functional and smoke test as shown in the previous chapters 'On board
test' and ‘Factory test with smoke generator’.

Adapter

17 mm nut

19 mm nut

Figure 51: Manometer connected to Figure 52: Manometer connected to

siphon block VN180 header pipe

Then carry out a pressure measurement at the end of the suction system. The
engine including the oil pump must be at standstill.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 52

Attention: You will only measure correct values at standstill

of the engine and the lube oil pump.

On a VN115/93 and VN116/93 installation the tightness of the suction system can
be determined by a pressure measurement at the outer siphon blocks or at the end
of the header pipes.

This siphon block has an additional fitting for a manometer (see Figure 51). To
remove the 17 mm lock nut you have to counter the 19 mm nut with a jaw wrench.

The pressure measurement procedure can also performed at the end of the 22 mm
diameter suction pipes which are delivered from SCHALLER AUTOMATION. These
pipes have also fittings for the manometer at the pipe end (see Figure 52).

Use only a digital manometer with a differential measuring method. On completion

do not forget to lock all openings.

The minimal negative pressure values are defined in Table 6. They are only valid if
a negative pressure of 60 mm WC is adjusted at the measuring head.

VN115/93 6.5 mm WC
VN116/93 1.5 mm WC

Table 6: Minimal pressure values at the end of the suction system

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 53

7.4 Factory test at engine builder with fog machine on VN215/93

installations

This test includes the indication of an oil mist alarm as well as the indication of the
affected compartment. Instead of the above mentioned smoke generator you have
to use the more powerful fog machine (see Figure 53) with a fog bag with adapter
(see Figure 54).

Figure 53: Fog machine Figure 54: Fog bag adapter

This equipment guarantees a constant fog concentration during the test and due to
high density no influence of the additionally sucked in crankcase atmosphere.

Due to the increasing request of the ship owners and classification societies to test
the OMD-system at running engines SCHALLER AUTOMATION recommends now
following procedure.

The first test must be performed at standstill to secure, that the engine is well
protected by the OMD system. If it is not possible to open the service covers or if it
is not possible to access the suction funnels, e.g. on large 2-stroke engines, a
functional test can be preformed alternatively using a special connection on the
siphon block or respectively on the T-engine wall connection.

Fill the fog bag completely with fog and close the adapter with the yellow cap. The
next step is to press the flexible hose of the fog bag adapter over the opened plug
at the side of the siphon blocks as seen in Fehler! Verweisquelle konnte nicht
gefunden werden. or over the open tube end at T-engine wall connections. Do
not remove the hose until an oil mist alarm is indicated and the search run to
indicate the affected compartment is finished. The plugs can be countered by an 11
mm jaw wrench to open or close the lock screw.

Attention: You have to test all compartments and the

additional suction points.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 54

The second test can be performed on request at running engine using the plugs of
the siphon block or the T-engine-wall connection to induce the fog.

Plug

Lock screw

Figure 55: Test inlet on the siphon blocks VN280

A wrong compartment indication can be caused either by:

x Empty fog bag: Æ Repeat the test with a full bag or
x Empty siphon block Æ Drain all siphon blocks of the
affected side completely by opening the 4 screws on
the front side and refill the siphons again.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 55

8 Spare Parts and Accessories

Part-No. Description Min. Quantity

10950 Service box 1
11201 Measuring head VN115/93; 33k; sensitivity level 4 * 1
11401 Measuring head VN116/93; 33k; sensitivity level 4 * 1
10901 Measuring head VN215/93; 33k; sensitivity level 4 * 1
10968 Control cover measuring head series VN93 devices 1
11432 Valve box VN116/93 1
10902 Valve box VN215/93 1
11094 Air filter for pressure regulator unit 1
Filter Scavenging air filter (6 pcs.)
Package
11055 Bottle with cleaning fluid 1
Cleaning Cleaning needle
Package
Cotton buds to clean IR-filters (5 pcs.)
11056 U-pipe manometer 1
Pressured Manometer adapter for siphon block VN180
Air Check
Bottle with slacked water
Package
Manometer adapter for control cover
11057 Gasket for valve box 1
Sealing Sealing for oil draining in valve box
Package
Sealing for suction channel in valve box (2 pcs.)
11058 Fuse cap 1
Fuse Semi lag fuses 3.15A (10 pcs.)
Package
VN93
11059 Bellow of suction channel (2 pcs.) 1
Bellow Bellow of scavenging air channel
Package
VN93
10409 Clamp plate VN215 valve box connection 2
10411 Rubber insert for valve box pipe connection VN215 2
10412 Rubber plugs for unused valve box connections 3
10905 Main connector socket 1
10975 Scavenging air inserts with metal bush (2 pcs.) 1
Scavenging air inserts for measuring heads delivered as

from cw27/2009 ( ) (2 pcs.)

cw year

Table 7: Spare parts

* Other versions are also available on enquiry.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 56

Part-No. Description
10950 Service box series VN93
11048 Commissioning box series VN93
10980 Manual series VN93
11045 Manual CD series VN93
10001 Pressure regulator unit with input throttle
10753 Protection cover
11163 Oil separator for air outlet
11164 Pipe siphon
10140 Siphon block VN280 1 connection
10142 Siphon block VN280 2 connection
10143 Siphon block VN280 3 connection
10144 Siphon block VN280 4 connection
10145 Siphon block VN280 5 connection
10141 Siphon block VN280 1 connection with manometer fitting
10160 Mounting plate VN280
11062 Oil pump VN280
10091 Blind plug VN280
10013 Siphon block VN180
10612 Siphon block VN180 with manometer fitting
10089 Mounting plate VN180
10062 Oil pump VN180
10640 Blind plug VN180
10353 Smoke generator 230 Volts
11089 Smoke generator 110 Volts
10097 Smoke fluid
11049 Fog machine complete
11052 Fog fluid
11072 Test-plate kit
11506 Monitoring device Remote Indicator II
11503 Bus-cable 10m for monitoring devices
Depends on engine type Suction funnel
Depends on engine type Engine wall connection

Table 8: Accessories

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 57

Figure 56: Service box 10950

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 58

Item Description Quantity

01 Hex key 5 mm L-shape 1
02 Fuse 3.15 A semi time lag 10
03 Scavenging air filters 6
04 Rubber plugs for unused valve box connections 3
05 Bottle with slacked water 1
06 Bellows of suction channel 2
07 Sealing for suction channel in valve box 2
08 Screwdriver 3 mm 1
09 Bottle with cleaning fluid 1
10 Clamp plate VN215 valve box connection 2
11 Air filter for pressure regulator unit 1
12 Sealing for oil draining in valve box 1
13 Manometer adapter for siphon block VN180 1
14 Manual series VN93 in English 1
15 U-pipe manometer 1
16 Philips screwdriver 1
17 Double jaw wrench 14/17 mm 1
18 Hex key 4 mm with handle bar 1
19 Gasket for valve box 1
20 Hex key 6 mm L-shape 1
21 Rubber plate for VN215 valve box connection 2
22 Manometer adapter for control cover 1
23 Scavenging air inserts with metal bush 2x2
Scavenging air inserts for measuring heads delivered as from
cw27/2009 ( cw year )

24 Cleaning needle 1
25 Bellow of scavenging air channel 1
26 Cotton buds to clean IR-filters 5

Table 9: Contents of service box series VN93

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 59

Figure 57: Commissioning box series VN93

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 60

Item Description Quantity

01 Test glass and test plate 1
02 Working instruction 1
03 Manometer adapter for control cover 1
04 Manual CD series VN93 1
05 Air filter for pressure regulator unit 2
06 Scavenging air inserts for measuring heads 2
07 Fresh air filters 6
08 Cotton buds to clean IR-filters 10
09 Cleaning needle 6
10 U-pipe manometer 1
11 Bottle with slacked water 1
12 Bottle with cleaning fluid 1

Table 10: Contents of commissioning box series VN93

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 61

9 Technical data

Mechanical data
Dimensions See drawings (Figure 58 to Figure 63)
Weight VN115/93 9 kg
VN116/93 11 kg
VN215/93 11 kg
Display LED-bar with 14 LED's
1 green Ready LED
1 red Alarm LED
1 red Test LED
2 x 4 alpha-numerical displays
Suction pipes VN115/93 ø 22 x 2 x max. 9m
VN116/93 ø 22 x 2 x max. 9m
VN215/93 ø 14 x 2 x max. 9m
Pipe connections VN115/93 2 x G1/2 or G3/4
VN116/93 2 x G1/2 or G3/4
VN215/93 10 x ø 14
Venturi injector connections In NTP/BSP/G1/2A
Out NTP/BSP/G3/4A
Pressure reducer connections In NTP/BSP/G1/4A
Out NTP/BSP/G1/4A
Air pressure Before pressure reducer 2 – 15 bar
Before air jet pump max. 500 mbar
Negative pressure in measuring head - 60 mm WC or – 6 mbar
Air consumption Depends on the suction system (about.
1 m3/h)
Electrical data
Power supply 18 Volts – 31.2 Volts DC, max. 3 A
Nominal voltage 24 Volts DC
Relay Outputs 2 x 'Alarm'
1 x 'Ready'
1 x 'Pre-Alarm'
(max. 60 Volts DC/AC, 60W, 125VA, 2A)
Cable entry 2 x M25
Communication interface to monitoring 2 wire RS485, galvanic separated
device

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 62

Communication cable recommendation LAPPKABEL UNITRONIC-FD CP (TP) plus

UL-CSA, 2 x 2 x AWG20, max 400 m
length, 7.5-10.0mm Ø
Environmental conditions
Operating temperature 0 - 70 °C
Storage temperature -25 – 80 °C
Max. vibrations 4 g (25-100Hz)
Relative humidity up to 95%
Protection class IP54
Approval of classes
Type approved for closed areas,
designed for installation on combustion
engines, environmental category D (GL),
IACS UR M67 conform, list of type
approvals see www.schaller.de

Table 11: Technical data

Figure 58: Mechanical dimensions of VN115/93: side view

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 63

Figure 59: Mechanical dimensions of VN115/93: top view

Figure 60: Mechanical dimensions of VN116/93: side view

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 64

Figure 61: Mechanical dimensions of VN116/93: top view

Figure 62: Mechanical dimensions of VN215/93: side view

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 65

Figure 64: Drilling template of the OMD base plate

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN93 05/2009
Page 66

10 Service Partners

Schaller Automation maintains a worldwide network of service partners currently in

the following countries:

Australia
Brazil
China
Denmark
Germany
Greece
Italy
Japan
South Korea
Netherlands
Norway
Poland
Singapore
Spain
United Arabian Emirates
United Kingdom
United States of America

For an up-to-date list of our representatives including address and contact details
please visit our website:

www.schaller.de

Alternatively, you may call the German headquarters for assistance in locating your
nearest representative.

Tel. +49 (0)6842 508 0

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de