Pyroban Gascheka duo System 5000 Operation Manual

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DATE

07.04.2015

10.09.2015

Gascheka duo™ System

Operation - Installation - Servicing

transmitted in any form or by any other means, electronic, mechanical, photocopying or

otherwise, without prior permission from Pyroban Limited.

Pyroban Ltd

Dolphin Road

Shoreham by-Sea

West Sussex

BN43 6QG

Telephone: +44 (0) 1273 456800

www.pyroban.com

E-mail:

service@pyroban.com

CHANGE

Initial release

Update to installation instructions

Part number PM1083ENG

Issue 1 Page 1 of 32

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Summary of Contents for Pyroban Gascheka duo System 5000

Page 1: Operation - Installation - Servicing
All rights reserved. No parts of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from Pyroban Limited. Pyroban Ltd Dolphin Road...
Page 2: Table Of Contents
Appendix 1 – Specification ....................... 29 Appendix 2 – Spares ......................... 30 Appendix 3 – pellistor head relative response ................31 Appendix 4 – infrared head relative response ................32 Copyright Pyroban Ltd. Issue 1 Page 2 of 32 Part number PM1083ENG...
Page 3: Introduction
IMPORTANT INFORMATION The Pyroban Pellistor Gas Sensing Head has a high level of poison resistance, but it may be irreversibly damaged by certain materials. These materials will increase the replacement frequency of the Gas Sensing Head.
Page 4: Contact Information
Contact information For any questions or concerns about this or any other Pyroban products or services, please do not hesitate to contact us. Pyroban Ltd Endeavour Works, Dolphin Road Shoreham-by-Sea, West Sussex, BN43 6QG United Kingdom Phone: +44 (0) 1273 456800 E-mail: service@pyroban.com...
Page 5: System Overview
Infrared or pellistor gas sensing heads can be specified depending on the potential gases that may be present. * LEL (Lower Explosion Limit); the weakest mixture of gas in air that will support an explosion. Copyright Pyroban Ltd. Issue 1 Page 5 of 32 Part number PM1083ENG...
Page 6: Components
This check process confirms the correct operation of the Gas Infrared gas detection head Sensing Head before each use of the vehicle. If this test is failed, the equipment will not be able to operate. Copyright Pyroban Ltd. Issue 1 Page 6 of 32 Part number PM1083ENG...
Page 7 Electronic button key The Electronic Button Keys (Dallas keys) are applied to the Control Unit to control the Gascheka duo system. Colour- coded keys are provided with the Gascheka duo. Copyright Pyroban Ltd. Issue 1 Page 7 of 32 Part number PM1083ENG...
Page 8: Limitations Of Use
Gas Sensing Head (See recommended spares). The Pyroban standard limited product warranty for Gascheka duo does not cover the Gas Sensing Head in environments where the materials that might damage the sensing head are present.
Page 9: Warnings Related To Operational Use
Warning – the Control unit and Relay unit must only be cleaned with a damp cloth. • The Relay unit cable gland diameter accommodation is 5.0mm to 8.0mm. Copyright Pyroban Ltd. Issue 1 Page 9 of 32 Part number PM1083ENG...
Page 10: Operating Instructions
2. Check the general condition of the vehicle and Pyroban equipment as defined in the Routine Servicing section of this manual. 3. Ensure the valve on the Pyroban test gas cylinder is turned to the ON position and that the cylinder is not empty.
Page 11: Starting Gascheka Duo
The red key should not be kept with the equipment, but be held by the person responsible for site safety. Copyright Pyroban Ltd. Issue 1 Page 11 of 32 Part number PM1083ENG...
Page 12: Operating The Vehicle
A shutdown or imminent delayed shutdown is identified by operation of the sounder and a red triangle (on solid). Refer to the original vehicle operator manual for further guidance on operating the vehicle. Copyright Pyroban Ltd. Issue 1 Page 12 of 32 Part number PM1083ENG...
Page 13: De-Activating The System
When the system is not being used it is recommended practice to switch off the Gascheka duo isolator to preserve battery charge. This is especially important on vehicles with 12V electrical systems Turn off the test gas bottle valve. Copyright Pyroban Ltd. Issue 1 Page 13 of 32 Part number PM1083ENG...
Page 14: Explanation Of Vehicle Shutdown And Control Unit Warnings
BRING THE VEHICLE TO A CONTROLLED STOP. Inform the Person in Authority. Copyright Pyroban Ltd. Issue 1 Page 14 of 32 Part number PM1083ENG...
Page 15: Installation Diagram
NSTALLATION Installation Diagram Copyright Pyroban Ltd. Issue 1 Page 15 of 32 Part number PM1083ENG...
Page 16: Preparation
Spanners - 8,10,13,17 & 19mm Gas bottle regulator spanner Hole cutter for Isolator Switch Metric Allen Keys (2.5mm & 3mm) Wire strippers Wire Cutters Crimp tool (Press Master RS 533-279) Terminal screwdriver Copyright Pyroban Ltd. Issue 1 Page 16 of 32 Part number PM1083ENG...
Page 17: Location Of Components
M8 bolts supplied. Failure to do this may cause the system to fail the automated gas response test and compromise response time. Copyright Pyroban Ltd. Issue 1 Page 17 of 32 Part number PM1083ENG...
Page 18: Test Gas Cylinder
Where such materials are present in the environment the Pellistor Gas Sensing Head will not be covered by Pyroban warranty protection. Test Gas Cylinder 1. Position the gas bottle where the pressure gauge is visible and where the vehicle provides mechanical protection.
Page 19: Relay Unit
If a replacement cable is used, this must be rated for the maximum system voltage with a minimum 8A current rating taking into account the ambient temperature. Copyright Pyroban Ltd. Issue 1 Page 19 of 32 Part number PM1083ENG...
Page 20 J2/6 7 If timeout is not selected, Gascheka duo will remain in Drive mode indefinitely. The ability to shut the vehicle down will not be affected by either mode. Copyright Pyroban Ltd. Issue 1 Page 20 of 32 Part number PM1083ENG...
Page 21 Gas Sensing Head using the tube provided. Cut to the length required and secure to the vehicle; cover with the spiral wrap if added protection is required. Copyright Pyroban Ltd. Issue 1 Page 21 of 32 Part number PM1083ENG...
Page 22 22. Check the operation of the red ‘supervisors’ key following gas shut down. (Refer to the Operating Instructions). 23. The Gascheka duo system is now ready for operation. 24. Peel the protective backing off the two Pyroban Gascheka duo labels and stick one to each side of the vehicle.
Page 23 – E.G. on Control Panel 27. Distribute blue/green operator’s key(s) and red supervisor’s key as appropriate. Copyright Pyroban Ltd. Issue 1 Page 23 of 32 Part number PM1083ENG...
Page 24: Servicing
Relay Unit. Annual Safety Audit Pyroban recommend an annual safety audit (ASA) by a Pyroban engineer to confirm the Gascheka duo System is functioning correctly and to advise on any matters arising from the audit. Contact Pyroban Service department on +44 (0) 1273 456800 for further details Copyright Pyroban Ltd.
Page 25: Trouble Shooting Guide
Replace Control Unit. • • Not applicable Not applicable • • RAM failure Replace Control Unit. • • EPROM failure Replace Control Unit. • • EEPROM failure Replace Control Unit. Copyright Pyroban Ltd. Issue 1 Page 25 of 32 Part number PM1083ENG...
Page 26 Denotes that indicator is flashing. Fault – refer to manual. Gas test phase ( 1,2 or 3) Flammable material in atmosphere 7 segment status indicator Sounder is active Copyright Pyroban Ltd. Issue 1 Page 26 of 32 Part number PM1083ENG...
Page 27 Restart Gascheka duo™ in the normal way, using either the green or blue key. Automated gas test failure. Investigation required. Pyroban equipment and vehicle disabled. The Person in Authority must be informed. The green Test indicators (1, 2, 3 ) will show the test at which the automated gas test failed.
Page 28 During the 10 minute timeout warning period Gascheka duo™ may be reset by placing the green or blue operator Dallas key on to the key receptor on the Control module or by movement of the vehicle. Copyright Pyroban Ltd. Issue 1 Page 28 of 32 Part number PM1083ENG...
Page 29: Appendix 1 - Specification
Gas Sensing Head IP54. The front of the Gas Sensing Head must be protected from road spray and power washing. Delayed shutdown timing options 10S, 15S, 20S, 25S (± 10%) Copyright Pyroban Ltd. Issue 1 Page 29 of 32 Part number PM1083ENG...
Page 30: Appendix 2 - Spares
2 – S PPENDIX PARES Pyroban supplied parts must be used (unless marked *) Item Pyroban part number Control Unit 815596/1/G Relay Unit 12V 815859/12V Relay Unit 24-80V 815859 Gas Sensing Head, Pellistor 815950 Gas Sensing Head, Infrared 813813 Gas Bottle 0.5l...
Page 31: Appendix 3 - Pellistor Head Relative Response
31.12% Ethylene 21.79% Heptane 43.57% Hexane 39.10% Isopropanol 38.13% Methane 15.25% Methanol 21.18% Pentane 36.31% Propanol (propion aldehyde) 41.22% Propane 25.00% Toluene 43.57% Vinyl acetate 39.10% Xylene 58.65% Copyright Pyroban Ltd. Issue 1 Page 31 of 32 Part number PM1083ENG...
Page 32: Appendix 4 - Infrared Head Relative Response
53.4 Methanol 22.7 Isopropanol 40.4 n-Heptane 31.2 n-Propanol 36.4 n-Propyl acetate 41.0 Butane 30.5 Isobutane 20.6 n-Octane 36.0 2,2,4-Trimethyl Pentane 30.8 n-Butyl alcohol 42.5 Propane 25.0 Ethane 29.4 Copyright Pyroban Ltd. Issue 1 Page 32 of 32 Part number PM1083ENG...