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Summary of Contents for Schaller Automation GasMOS 180516
- Page 1 GasMOS ® Gas Monitoring System - Operating manual - - 180516 -...
- Page 2 Dear customer, this operating manual is intended for all those who work/will work on/with the system described here. They require knowledge of this operating manual to avoid faults in the system and to operate the system without issues. They must therefore have knowledge of this operating manual.
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Page 3: Table Of Contents
Table of contents Technical data and scope of delivery ..............5 Identification ...................... 9 Product brand and type designation ..............9 Manufacturer ....................10 Type plate ......................10 Product description and technical data ............11 2.4.1 Product description ..................11 2.4.2 GasMOS Gas Monitoring System .............. - Page 4 5.1.8 Replacing the filter element of the environmental air input....... 61 5.1.9 Leak test of the device's particle filter.............. 62 Repair by the operator ..................65 Repair by Schaller Automation................. 65 Taking out of service and disassembly ............65 Storage ......................65 Packaging ......................
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Page 5: Technical Data And Scope Of Delivery
Technical data and scope of delivery Electrical interfaces/power supply Input Output environmental air calibration Figure 1: Connections on bottom of device Figure 2: Device open... -
Page 6: Figure 3: Device With Dimensions
Figure 3: Device with dimensions... -
Page 7: Figure 4: Mechanical Interfaces
Mechanical interfaces Dimensions Approx. 310 x 450 x 175 mm Weight 13.00 kg Pipe connection/hose connection Ø10 Pipe connection/hose connection Ø10 Pipe connection/hose connection G3/8 Through hole Ø9.25 Flow rate 1 l/min ± 10% Figure 4: Mechanical interfaces Electrical interfaces Power supply 18 –... -
Page 8: Figure 6: Environmental Conditions
Environmental conditions Ambient temperature range 0 to 50 °C Storage temperature range -20 °C to 50 °C Recommended: 5 °C to 50 °C Avoid condensation Relative humidity up to 70% Protection rating IP 54 −0 Vibrations – 13.2 Hz: ±1.0 mm 13.2 –... -
Page 9: Identification
Identification Product brand and type designation This operating manual is valid for the GasMOS ® Gas Monitoring System. The Gas Monitoring System is designed for use in potentially explosive atmospheres in accordance with ATEX/IECEx. ATEX: II 2/-G Ex ib db IIA T1 Gb/- •... -
Page 10: Manufacturer
Manufacturer Schaller Automation Industrielle Automationstechnik GmbH & Co. KG Industriering 14 66440 Blieskastel Germany Type plate Figure 10 GasMOS type plate... -
Page 11: Product Description And Technical Data
Product description and technical data 2.4.1 Product description The GasMOS Gas Monitoring System from SCHALLER AUTOMATION is used to continuously measure the methane content within the gas atmosphere of the crankcase of large engines (gas and dual fuel). The Gas Monitoring System generates negative pressure with a built-in pump and draws in the sample gas from the crankcase. -
Page 12: Gasmos Gas Monitoring System
2.4.2 GasMOS Gas Monitoring System Figure 11 GasMOS exterior view (1) Housing (7) Electrical connection cable input (2) Display (8) Electrical connection cable input (3) Button (9) Electrical connection cable input (4) Sample gas input/intake (10) Pressure equalisation element (5) Sample gas output/return (11) Earth connection M8 (6) Sample gas input/intake... -
Page 13: Figure 12 Gasmos Interior View
Figure 12 GasMOS interior view Filter Pump Pressure compensation element for pulsation damping Sensors: GESM module Valve Protection cover Cable duct WARNING! Explosion of the crankcase Serious injury, including death The GasMOS Gas Monitoring System is designed to draw in gases from a potentially explosive atmosphere (for example, the crankcase of a gas engine). -
Page 14: Figure 13: Interface Schematic
The Gas Monitoring System primarily consists of a housing (1) which has a display unit (2), a sample gas input (4), a sample gas output (5) and cable glands (7, 8, 9). The Gas Monitoring System also contains an interface for calibration and environmental air calibration (6), which is protected by a filter during normal operation. - Page 15 The Gas Monitoring System can be connected directly to the engine's control system. The interface has a relay output for any exceeding of the set warning threshold, a ready-for- operation signal (System Ready), an electrically isolated input (24 V) for distinguishing between diesel/gas operation, and an electrically isolated input (24 V) for detecting engine operation.
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Page 16: Housing
Housing The housing has wall brackets. These are used to mount it on a wall. The device is only suitable for mounting on walls that have flat, solid and continuous surfaces. Select fasteners with sufficient strength and that are appropriate to for the subsurface. Figure 14Rear of the GasMOS The hole diameter on the wall brackets is 8 mm (Figure 15). -
Page 17: Figure 15Hole Diameter On Wall Bracket
Ø 8 Figure 15Hole diameter on wall bracket Figure 16 The housing is designed for a maximum load of F =250 Nm ( Figure 16: Max. load on housing (source: Rittal 3_8114) When the door is open, a maximum load of F =50 Nm is allowed on the door (Figure 17) -
Page 18: Pipe And Hose Lines
Figure 17: Max. load on open door (source: Rittal 3_8114) Pipe and hose lines Schaller Automation uses state-of-the-art equipment to draw in and transport the gaseous atmosphere. Therefore, only stainless steel pipes (tolerance ±0.1 mm) according to DIN EN 10216-5, stainless steel screw connections or PTFE hoses may be used to connect the Gas Monitoring System to the equipment being tested. -
Page 19: Safety And Protection Measures
Safety and protection measures The GasMOS Gas Monitoring System is manufactured according to Schaller Automation's high quality standards and undergoes strict factory tests. The safety instructions and warnings must be observed by the operator to ensure that the device operates smoothly and without problems. -
Page 20: 2.10 Guide To Symbols
2.10 Guide to symbols This operating manual uses the following symbols in accordance with DIN EN 82079-1. ATTENTION: Indicates important information which helps to avoid damage to property. CAUTION: Indicates a low-risk hazard that, if not avoided, may result in minor or moderate injury. -
Page 21: Installation
Installation Safety precautions before use DANGER! Explosion of the crankcase Serious injury, including death You may only install and remove the Gas Monitoring System when the engine is switched off. DANGER! Explosion of the crankcase Serious injury, including death ... -
Page 22: Unpacking, Items Included In Delivery
Unpacking, items included in delivery When the Gas Monitoring System is delivered, always check the delivery to ensure that it includes all the components. Schaller Automation provides you with a corresponding parts list for this purpose. Dispose of the packaging materials in accordance with your local disposal regulations in the containers provided for this purpose. -
Page 23: Electrical Assembly
3.4.3 Electrical assembly DANGER! Risk of electric shock Risk of injury Before connecting the electrical power supply lines, you must ensure that there is no voltage. The Gas Monitoring System can be connected to the operator's network and the operator's interfaces using the connection lines, as follows. -
Page 24: Pre-Wired Connectors
3.4.4 Pre-wired connectors The connectors for the pump and valves are pre-wired at the factory. Table 1 shows the assignments of the interfaces. J401 – Display Figure 19 Display connection J1101 – Pump J1101.1: +12 V J1101.2: Speed setting J1101.3: GND J1101.4: Tachometer signal Figure 20 Pump connection... -
Page 25: Wiring On Installation; Customer Interfaces
3.4.5 Wiring on installation; customer interfaces Connections for customer interfaces Power supply • Engine status • Relay contacts • Communication: CANopen or Modbus • GasMOS with assembled supply lines 1: Relay outputs, engine operation 2: Power supply 3: Communication Figure 22GasMOS with assembled supply lines Figure 22 shows the GasMOS Gas Monitoring System with the supply lines fully assembled. -
Page 26: Figure 23 Dimensions Of Supply Cables
J700 or J701 3.1: J1100 3.2: J1102 J200 Shieldi 7 - 13 4.5 - 9 mm 7 - 13 2 x ≥ 0.5 mm 8 x ≥ 0.25 mm 3 x ≥ 0.25 mm Prepare the cables before feeding them in. To do this, cut the cables and strip them to size. -
Page 27: Figure 24 Open Cable Duct
Remove cable duct cover Figure 24 Open cable duct Feed the cable through the provided cable gland. Figure 25 Feed in the cables... -
Page 28: Figure 26 Secure Cables To Prevent Them Slipping Out
Width across flats 24, M=12 Nm ±0.5 Nm Width across flats 20, M=10 Nm ±0.5 Nm Secure the cable to prevent it slipping out. To do this, tighten the cable gland hand-tight by hand or with a spanner. Figure 26 Secure cables to prevent them slipping out ... -
Page 29: Figure 28 Power Supply Connection
J200 J200.1: +24 V Power J200.2: GND supply Figure 28 Power supply Voltage range: connection 18 V - 31.2 V J700 J700.1: +5 V ISO CAN Bus J700.2: CAN L J700.3: GND ISO J700.4: CAN H Figure 29 CAN bus connection J701 J701.1: +3V3 ISO... -
Page 31: Figure 33: Connect Single Wires
J701 J700 J1103 Modbus Valves 8 6 4 2 7 5 3 1 10 8 6 4 2 9 7 5 3 1 J1102 Relay J200 Power J1100 J1101 supply Engine Pump status Connect the individual wires to the screw or spring-loaded terminals. Connect the terminals as per Table 2. -
Page 32: Figure 34: Procedure For Installing The Connection Cables
- Communication - Power supply - Relay outputs - Engine operation Repeat the procedure from Figure 25 to Figure 33 until all the required cables are connected. Figure 34: Procedure for installing the connection cables... -
Page 33: Figure 35Final Assembly Of The Cable Gland
Width across flats 24, M=12 Nm ±0.5 Nm Width across flats 20, M=10 Nm ±0.5 Nm Tighten the cable glands according to the specifications in Figure 35. Figure 35Final assembly of the cable gland Width across flats 13 Figure 36 Connecting the earth cable... -
Page 34: Starting Up For The First Time
Starting up for the first time WARNING! Engine protection not guaranteed Danger of explosion The Gas Monitoring System may only be started up after all the components have been completely attached. If the device as been stored in a cold place (T<0 °C) before starting up for the first time, wait until the device has reached ambient temperature before starting it up. -
Page 35: Starting Up Again
In this case, the GasMOS Service app displays the following error message: “MEASUREMENT FLOW BOUND ERROR”. On the device display, the “System ready” LED goes off and the “System failure” LED comes on. See Figure 40 for the start sequence of the device. After switching on, the system runs through a boot sequence. -
Page 36: Operation And Use
Operation and use Operating statuses Figure 41 lists and describes the operating statuses of the GasMOS measuring system. System System Sensor Service Warning Button Status ready failure ready required notice Measuring mode operating mode Device “Off” Self-diagnosis/environmental air calibration/maintenance Methane warning Error Measuring measured value for methane, oxygen active. -
Page 37: Figure 43: Gasmos Front Panel In Operation Mode
Before Operation mode is active when the device is first started, a boot sequence and a subsequent self-check (“SELF_CHECK”) runs first. Figure 43: GasMOS front panel in Operation mode In normal measuring mode, the “System ready” and “Sensor ready” LEDs are on. -
Page 38: Methane Concentration Warning
Methane concentration warning The “Warning notice” LED comes on and the illuminated ring around the “METHANE CONCENTRATION CONFIRMATION” button flashes red. The “System ready” LED goes off. If the warning threshold stored on the device is exceeded, the alarm on the Gas Monitoring System must be reset manually to the ready-to-operate status. -
Page 39: Self-Diagnosis" Mode
“Self-diagnosis” mode Self-diagnosis is carried out at regular intervals from “Operation” mode. Self-diagnosis also runs on the following events: Return from “MAINTENANCE” mode • Periodic triggering from “ERROR” mode • In this case, the “System ready” LED on the device display goes off (Figure 45). Figure 45 Sensor OK, system not ready Figure 46 shows the self-check sequence. -
Page 40: Figure 46: Self-Diagnosis Sequence
Start self_check READY relay off, ready LED off Switch to “SELF_CHECK_PSU_ERROR” Power supply environmental air error > U Supply Engine in gas mode? Electrical power “SELF_CHECK_FAILED” error consumption “ERROR” mode measurement of CH and O Measurement run > 3 min. from start? Check whether environmental air... -
Page 41: Environmental Air Calibration Mode
Environmental air calibration mode Environmental air calibration runs automatically every day. It is the basis for automatic offset correction of the methane measurement. During environmental air calibration, the “System ready” status is cancelled and the device is not ready for measurement. Figure 47 shows the environmental air calibration sequence. -
Page 42: Figure 47Environmental Air Calibration Sequence
Start environmental air calibration READY relay off, ready LED off Switch to environmental air Start methane measurement Max. duration of “ENV_AIR_CALIB_DURATION_ environmental air EXCEEDED_ERROR” calibration complied with? “ENV_AIR_CALIB_ERROR” Min. duration of environmental air calibration complied with? Permanent error until device restart History and “ENV_AIR_CALIB_RESULT current offset... -
Page 43: Maintenance Mode
Maintenance mode Maintenance mode is started via the GasMOS Service app. To start this mode, the GasMOS device has to be connected by USB cable to a computer on which the GasMOS Service app is installed. Maintenance mode is started via the GasMOS Service app from the “Final inspection, Activate maintenance mode”... -
Page 44: Error Diagnosis And Troubleshooting
Error diagnosis and troubleshooting DANGER! Risk of explosion due to methane. Severe to fatal injuries. If a warning message is displayed, do not approach the engine again until the methane concentration has dropped below the warning threshold. This is indicated by the device if, after you have acknowledged the warning message, the measuring system does not enter the warning status again after waiting 30s. -
Page 45: System Ready" Led Not On, "Sensor Ready" Led Is On
“System ready” LED not on, “Sensor ready” LED is on In this case, the device is in one of the following operating statuses: Self-check • Maintenance • Environmental air calibration • Boot • Alarm (alarm relay set) • The “Sensor ready” LED indicates that the measured value calculation for methane and oxygen is active. -
Page 46: System Ready" Led Not On, "System Failure" Led Is On
In these cases, the device should be restarted (disconnect the power supply for 5 seconds). If the error occurs again after restarting the device, the device must be checked by a service employee or sent to Schaller Automation for inspection. Figure 49 Device in error mode 4.10 “Sensor ready”... -
Page 47: Service Required" Led Comes On
Maintenance cycles for reliable operation The maintenance cycles for the GasMOS system are listed in the table below (Figure 50). With regular maintenance, Schaller Automation guarantees that the product will have a long service life. If the maintenance intervals are not observed, the sensor may fail prematurely. -
Page 48: Figure 50 Maintenance Intervals
Check/replace pump Check/replace valve Calibrate GESM Replace environmental air filter Key to maintenance measures – Work that must be done – Optional; only if the pre-filter is installed SAB – By Schaller Automation only Figure 50 Maintenance intervals... -
Page 49: Maintenance By The Operator
For maintenance, please contact Schaller Service (for contact details, see Section 7). To ensure that the device functions properly, the device must regularly undergo factory calibration (Annual inspection). For this calibration, the device must be removed and sent to Schaller Automation. 5.1.4 Checking for contamination in the sample gas path The path of the sample gas supply line (lines, including sample gas filter) should be checked for contamination at regular intervals (see Table 3). -
Page 50: Figure 51 Checking The Device For Contamination
Test the device for contamination Is the sample gas filter dirty? Is the line downstream Service required of the sample Section 5.1.3 gas filter dirty? Line leading to sample gas filter dirty? Leak test of device Service required possible? Section 5.1.3 Remove the lines and clean them. -
Page 51: Cleaning The Device Filter
5.1.5 Cleaning the device filter Dust deposits on the filter must be removed regularly (weekly). Clean the filter from the outside and only with a clean, damp cloth (do not use cleaning products that contain solvents). DANGER! Sparking due to electrostatic charge (risk of explosion) Severe to fatal injuries due to explosion of the crankcase ... -
Page 52: Figure 52 Releasing The Filter Bowl Lock
Particle filter maintenance kit 12 S2 filter elements, 12 Viton sealing rings, 12 environmental air filters (environmental air input) Spare part: Filter bowl Release the filter bowl lock by pulling out the black bracket. Figure 52 Releasing the filter bowl lock... -
Page 53: Figure 53 Removing The Filter Bowl
Remove the filter bowl. Figure 53 Removing the filter bowl Replace the filter element. Figure 54 Replacing the filter element... -
Page 54: Figure 55 Cleaning The Filter Bowl, As Necessary
If necessary, clean the inside of the filter (filter glass, filter insert receptacle) with a soap solution, then rinse with clear water so that there is no soap residue left inside, and dry. The filter insert may only be inserted and the filter glass mounted when the inside area is dry. -
Page 55: Figure 57 Pushing On The Filter Bowl
Press the filter bowl into the top part of the housing until the seal is no longer visible. Figure 57 Pushing on the filter bowl Lock the filter bowl with the bracket Figure 58 Inserting the filter bowl retaining bracket... -
Page 56: Replace The Filter Element Of The Pre-Filter (Coalescing Filter)
5.1.7 Replace the filter element of the pre-filter (coalescing filter) ATTENTION! Perform maintenance only when it has cooled down! DANGER! Gas in the filter, condensate or even used filter elements can be toxic or corrosive Sample gas can be hazardous to health. ... -
Page 57: Figure 59 Releasing The Filter Bowl Lock On The Coalescing Filter
Release the filter bowl lock by pulling out the black bracket. Secure the filter bowl to prevent it falling down. Figure 59 Releasing the filter bowl lock on the coalescing filter Remove the filter bowl. Figure 60 Removing the filter bowl on the coalescing filter... -
Page 58: Figure 61 Removing The Filter Element
Remove the filter element with the support tube Remove Install Figure 61 Removing the filter element Pull the filter element (1) off the support tube (2). Clean the support tube if it is dirty, using a soap solution. -
Page 59: Figure 63 Change Seal
Remove Viton seal and fit new seal Figure 63 Change seal Mount the filter bowl by pushing it on. If dirty, clean with soap solution and rinse with clear water. Dry before installation Figure 64 Pushing on the filter bowl on the coalescing filter... -
Page 60: Figure 65 Locking The Filter Bowl Of The Coalescing Filter
Lock the filter bowl with the bracket by inserting the bracket. Figure 65 Locking the filter bowl of the coalescing filter... -
Page 61: Replacing The Filter Element Of The Environmental Air Input
5.1.8 Replacing the filter element of the environmental air input Pull back the plug-in connection environmental air input lock (1) Remove the filter element (2) Figure 66 Replacing the filter element of the environmental air input Push on a new filter element Figure 67 Replacing the filter... -
Page 62: Leak Test Of The Device's Particle Filter
Leak test of the device's particle filter After replacing a filter element, check the device for leaks. You can purchase a “Leak test” kit from Schaller Automation to do this. Below is a description of the leak test using this kit. -
Page 63: Figure 69 Connecting The Test Pump
Unscrew the sample gas input line on the engine. Attach the test pump connection line. Tighten the fitting by hand. Tighten with 45° with spanner Open Close Width across Figure 69 Connecting the test pump Apply overpressure of 250 mbar ±30 mbar. -
Page 64: Figure 71 Test Path, Max. Allowed Pressure Drop
Test path on voltage- free device, marked yellow t= 3 min Δp < 100 mbar Δp > 100 mbar Figure 71 Test path, max. allowed pressure drop... -
Page 65: Repair By The Operator
Repair by the operator Repair by the operator is not possible. If the device or components of the device are defective, the device must be removed and sent to Schaller Automation for repair (Section 5.3). ATTENTION! Early failure of the methane detector Dirty parts increase the risk of device failure. -
Page 66: Spare Parts, Maintenance Kits
Spare parts, maintenance kits 5.7.1 GasMOS spare parts list Figure 72: Exploded view of the GasMOS Figure 73: Pre-filter... -
Page 67: Figure 74 Spare Parts
GasMOS spare parts and maintenance parts Item Material number Description Quantity Maintenance kit for internal particle filter - S2 filter elements, 12 pcs. 273504 - Viton sealing ring for filter, 12 pcs. - Silencer for environmental air input, 12 pcs. Maintenance kit for coalescing filter pre-filter 273505 - S2 filter elements, 12 pcs. -
Page 68: List Of Figures
List of figures Figure 1: Connections on bottom of device ................5 Figure 2: Device open ......................5 Figure 3: Device with dimensions ..................6 Figure 4: Mechanical interfaces ..................... 7 Figure 5: Electrical interfaces ....................7 Figure 6: Environmental conditions ..................8 Figure 7: Measuring range ..................... -
Page 69: Contact
Figure 53 Removing the filter bowl ..................53 Figure 54 Replacing the filter element ..................53 Figure 55 Cleaning the filter bowl, as necessary ..............54 Figure 56 Replacing the sealing ring ..................54 Figure 57 Pushing on the filter bowl ..................55 Figure 58 Inserting the filter bowl retaining bracket ..............55 Figure 59 Releasing the filter bowl lock on the coalescing filter ...........57 Figure 60 Removing the filter bowl on the coalescing filter ..........57 Figure 61 Removing the filter element ..................58...
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