VISATRON OIL MIST DETECTORS VN115/87PLUS, VN116/87 PLUS, VN2 Installation instructions Caterpillar


Installation instructions
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1.1. Mechanical installation
2.2. Basics
3.2. Pipe dimensions
4.2. Installation of pipe siphons
5.2. Installation of the siphon block connection units
6.2. Suction funnels in the crankcase compartment
7.2. Pipe arrangement at valve box (VN215/87plus system only)
8.2. Compressed air connection
9.1. Electrical installation
10.2. VISATRON® series VN87plus device
11.2. Connection of monitoring devices
12.2. Schematic electrical wiring diagram

Mechanical installation

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.

Following rules are recommended by SCHALLER AUTOMATION:

* Use at least one suction point per compartment.
* Use always the long version of the suction funnels. This makes the installation independent from the rotation sense of the engine.
* At least one suction point per chain drive or gear drive is necessary.
* Avoid the splash oil disk of the crankshaft bearings.
* Select points in the upper area of the crankcase, as oil mist tends to rise upwards!
* The detection unit has to be placed above the suction points.
* Installation Rules: in general avoid U-bends or kinks in the tubing system.
* 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.
* VN115/116 with siphon blocks: Use one siphon block at each compartment.
* 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.
* VN215 without draining components: The pipes have to be mounted with an angle greater than 6° inclination.
*
* 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.
* If possible place the VISATRON® detection unit in the center of the engine to avoid long pipe runs.
* 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.
* 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.

Pipe dimensions

* For VN115 and VN116 standard applications:
* Seamless steel pipes: 22 mm outer diameter, 2 mm wall thickness
* Flexible hoses: inner diameter not less than 6 mm
* For VN215 standard applications:
* Seamless steel Pipes: 14 mm outer diameter, 2 mm wall thickness or, if 14 mm is not available
* Seamless steel Pipes: 13,71 mm (known as 1/4-inch pipes, schedule no. 40, 0.540 inch outer diameter, 0.088 inch wall thickness)

The length of exhaust air pipe (outlet of the venturi injector) should be limited to max. 4m. If a longer tube is required, please contact Schaller Automation. The inner diameter has to be > or = 18 mm. U-bends and kinks are forbidden.

All installation solutions must have written agreements by SCHALLER AUTOMATION as required by IACS UR M10.

Installation of pipe siphons

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

Installation of the siphon block connection units

Consider the following points:

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

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

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).

Pipe arrangement at valve box (VN215/87plus system only)

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 2-15 bar.

Electrical installation

VISATRON® series VN87plus 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.

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 fixings screw 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.

Also placed on the rear side two jumpers are available to select the interface mode: RS485 bus or 4- 20mA output of the relative opacity at pin 11 and 13.

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

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 up to 70% of the Oil Mist alarm level. Please note that depending on the characteristics of an oil mist occurrence, the time between 'Prealarm' and 'Main Alarm' could be only a fraction of a second.

* We recommend to connect 'Alarm' 1 to the alarm system and 'Alarm' 2 to the safety system.
* Alarms 1 and 2 are getting switched simultaneously by same relay.
* The relay outputs are potential-free.
* In case of a High Oil Mist Alarm, contacts 7 and 8 as well as 15 and 16 are closing
* In case detector goes into 'READY'-Mode, contacts 4 and 5 are closing
* In case Pre-Alarm is activated, contacts 9 and 10 are opening. Pre-Alarm will be switched as soon as 70% of High Oil Mist Alarm level is reached.

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.

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 following the installation instructions in the ReCon DS23 manual.

The monitoring device is the bus master and the OMD devices are the slaves. It's necessary to adjust different bus addresses at each slave device. Normally the first OMD device gets the address '1' and so on. The switch is on the rear side of the measuring head (see Figure 29).

Schematic electrical wiring diagram

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