SGB VL Series Operator's manual

Documentation
Vacuum leak detector VL ..
in 100–240 VAC and 24 VDC
Read instructions prior to commencing any work
As of: 01/2020
Item no.: 605 322

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Overview of the Design Variations
Vacuum leak detectors are available in different versions that are described more precisely by the
letters attached to them.
VL .. E FA P M MV LG LE S Si T
“Tightness alarm”
“Service Indication”: (LED) display with
variably adjustable service periods
“Service display”: integrated (LED) service
display with fixed 12-month interval
“LOD Ethernet”: Leak detector online diagno-
sis remote monitoring with Ethernet module
“LOD GSM module”: Leak detector online diagno-
sis remote monitoring with wireless module
“Solenoid valve” (MV): An MV with monitored func-
tion can be connected for applications with high
pressure in the inner pipe.
“Manometer”: The leak detector is equipped with a digital
pressure indicator in the housing cover.
“Protected”: Leak detector version in a weather-protected hous-
ing
“Filling level indicator”: An electronic filling level indicator is in-
tegrated in the leak detector
“Enhanced functions”: This version provides the option of connecting
additional equipment, such as a solenoid valve and/or a probe in the
leak detector.
“..” = numerical value stands for the alarm vacuum of the leak detec-
tor. The alarm pressures range from 34 mbar to 570 mbar.
“Vacuum Leak detector” for tanks. The leak detector operates with negative
pressure towards the atmosphere.
Variations/Options

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Table of Contents
1.General......................................................................................5
1.1Information........................................................................5
1.2Explanation of Symbols ....................................................5
1.3Limitation of Liability .........................................................5
1.4Copyright ..........................................................................5
1.5Warranty Conditions .........................................................6
1.6Customer Service .............................................................6
2.Safety ........................................................................................7
2.1Intended use .....................................................................7
2.2Obligation of the Operating Company ..............................7
2.3Qualification ......................................................................7
2.4Personal Protective Equipment (PPE)..............................8
2.5Fundamental Hazards ......................................................8
3.Technical Data of the Leak Detector ......................................10
3.1General Data ..................................................................10
3.2Electrical Data.................................................................10
3.3Switching Values ............................................................10
3.4Field of Application .........................................................11
4.Design and Function ...............................................................14
4.1Design.............................................................................14
4.2Normal Operating Condition ...........................................16
4.3Air Leaks.........................................................................16
4.4Liquid Leaks....................................................................16
4.5Pressure increase above atmospheric pressure in the
interstitial space when using a leak detector VL .. with
solenoid valve (MV) ........................................................16
4.6Displays and Controls.....................................................17
5.Mounting the System...............................................................19
5.1Basic Instructions............................................................19
5.2Assembly of the Leak Detector.......................................19
5.3Pneumatic Connection Lines ..........................................20
5.4Completing Pneumatic Connections...............................20
5.5Electrical Cables .............................................................21
5.6Electrical Wiring Diagram ...............................................22
5.7Installation Examples......................................................25
6.Commissioning ........................................................................31
6.1Tightness test .................................................................31
6.2Commissioning the Leak Detector..................................31
7.Functional Check and Maintenance.......................................33
7.1General ...........................................................................33
7.2Maintenance ...................................................................33
7.3Functional Check ............................................................ 34
8.Malfunction (Alarm) .................................................................39
8.1Alarm Description ...........................................................39
8.2Malfunction .....................................................................39
8.3How to Behave ...............................................................39
9.Spare Parts ...............................................................................40
Contents

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10.Accessories ............................................................................. 40
11.Appendix.................................................................................. 41
11.1Use of Interstitial Spaces That Are Filled with
Leak Detector Fluid.........................................................41
11.2Appendix W, Warmed Tanks ..........................................42
11.3Dimensions and Drilling Pattern......................................45
11.4Declaration of Conformity................................................47
11.5Declaration of Performance ............................................48
11.6Declaration of Compliance of the manufacturer (ÜHP)...48
11.7TÜV Nord Certification ...................................................49
Contents

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1. General
1.1 Information
These instructions provide important notes on using the leak detector
VL … Complying with all safety instructions and guidelines is a pre-
requisite for safe working.
Furthermore, any local regulations for prevention of accidents appli-
cable at the site of use of the leak detector and general safety instruc-
tions must be complied with.
1.2 Explanation of Symbols
In these instructions, warnings are marked with the adjacent symbol.
The signal word expresses the level of hazard.
DANGER:
Imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING:
Potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION:
Potentially hazardous situation which, if not avoided, could result in
minor or moderate injury.
Information:
Highlights useful tips, recommendations, and information.
1.3 Limitation of Liability
All information and instructions in this documentation have been
compiled considering the applicable standards and regulations, the
state of the art, and our longstanding experience.
SGB does not assume any liability in the case of:
Noncompliance with these instructions
Improper use
Use by unqualified personnel
Unauthorized modifications
Connection to systems not approved by SGB
1.4 Copyright
The contents, texts, drawings, images, and other representations are
copyrighted and subject to industrial property rights. Any misuse is
punishable.
General

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1.5 Warranty Conditions
We provide warranty for the leak detector VL .. for a period of 24
months from the day of installation on site in accordance with our
General Terms & Conditions.
The maximum warranty period is 27 months from our date of sale.
Warranty is subject to submission of the functional/test report on ini-
tial commissioning by qualified personnel.
Stating the serial number of the leak detector is required.
The obligation of warranty shall cease to exist in the case of
- inadequate or improper installation,
- improper use,
- modifications/repairs without consent of the manufacturer.
1.6 Customer Service
Our customer service is available for any inquiries.
For information on contacts, please refer to our website www.sgb.de
or the label of the leak detector.
General

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2. Safety
2.1 Intended use
Conditions from Section 3.5 “Field of Application” must be adhered
to.
Only for the interstitial spaces of double-walled tanks that show
sufficient vacuum resistance:
Grounding/equipotential bonding in accordance with applicable
regulations
Tightness of the interstitial space according to this documentation
(Section 6.1).
Assembly outside of the potentially explosive area only
Stored material needs to have a flash point of over 60°C (for Ger-
many > 55°C in accordance with TRBS and TRGS), i.e., the stored
material must not develop explosive vapor-air mixtures.
Ambient temperature -40°C to +60°C in the stainless steel housing
and 0°C to 40°C in the plastic housing
The power supply cannot be disconnected
Any claims arising from misuse are excluded.
2.2 Obligation of the Operating Company
The leak detector VL .. is used in the commercial sector. The operat-
ing company is therefore subject to statutory occupational safety obli-
gations.
In addition to the safety instructions in this documentation, all appli-
cable safety, accident prevention, and environmental regulations
must be adhered to. In particular:
oCompiling a risk assessment and implementing its results in a di-
rective
oPerforming regular checks as to whether the directive is in compli-
ance with the current standards
oThe directive includes information on how to react to an alarm that
might arise
oArranging for an annual functional check
2.3 Qualification
The personnel must be capable of independently recognizing and
avoiding potential risks based on their qualifications.
Companies commissioning leak detectors should have completed re-
spective training with SGB, through SGB, or its authorized repre-
sentative.
National guidelines must be adhered to.
For Germany: Technical service qualification for assembly, commis-
sioning, and maintenance of leak detection systems.
Safety
WARNING!
Danger from
misuse
WARNING!
Danger to hu-
mans and the
environment in
the case of in-
adequate quali-
fication
WARNING!
Danger in case
of incomplete
documentation

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2.4 Personal Protective Equipment (PPE)
Personal protective equipment must be worn during work.
oWear necessary protective equipment for the relevant work
oNote and comply with existing PPE signs
Entry in the “Safety Book”
Wear HV vest
Wear safety footwear
Wear hard hat
Wear gloves – where necessary
Wear safety goggles – where necessary
2.5 Fundamental Hazards
DANGER:
From electric current
When working on the leak detector, it must be disconnected from the
power supply unless stated otherwise in the documentation.
Comply with relevant regulations regarding electric installation, explo-
sion protection (e.g., EN 60079-17), and accident prevention.
CAUTION:
From moving parts
If work is being done on the leak detector, it must be disconnected
from the power supply.
Safety

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DANGER
From working in chambers
The leak detectors are mounted outside the access chambers.
Pneumatic connection is usually performed inside the access cham-
ber. Therefore, the chamber must be entered for mounting.
Before entering, the corresponding protective measures must be tak-
en and it must be ensured that no gas and sufficient oxygen are pre-
sent.
Safety

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3. Technical Data of the Leak Detector
3.1 General Data
Dimensions and drilling pattern see Section 11.3
Weight
Plastic housing 2.0 kg;
Stainless steel housing 4.5 kg
Storage temperature range -40°C to +60°C
Operating temperature range
Plastic housing 0°C to +40°C
Stainless steel housing -40°C to +60°C
Buzzer volume 70 dB(A) in 1 m
Housing protection class
Plastic housing IP 30
Stainless steel housing IP 54
Version without solenoid valve ≤5 bar (pressure in the inner tank)
with solenoid valve > 5 ≤25 bar (pressure in the inner
tank)
3.2 Electrical Data
Power supply 100 – 240 VAC, 50/60 Hz
or: 24 VDC
Power input 50 W (incl. heating)
Terminals 5, 6, external signal: max: 24 VDC; max. 300 mA
Terminals 11 – 13, potential free: DC ≤25 W or AC ≤50 VA
Fuse protection: max. 2 A
Overvoltage category: 2
3.3 Switching Values
Type Alarm ON, at
the latest:
Pump OFF,
not more than:
Functionality* of the
interstice given for
34 - 34 mbar - 120 mbar - 650 mbar
230 - 230 mbar - 360 mbar - 650 mbar
255 - 255 mbar - 380 mbar - 650 mbar
330 - 330 mbar - 450 mbar - 700 mbar
410 - 410 mbar - 540 mbar - 750 mbar
500 - 500 mbar - 630 mbar - 850 mbar
570 - 570 mbar - 700 mbar - 900 mbar
Special values can be agreed upon between the client and SGB.
Excess pressure alarm (only VL .. MV1) at + 50 mbar
* considered fulfilled for double-walled steel tanks; in principle, lower
values are possible, if need be with the use of a vacuum valve
1MV = solenoid valve
Technical Data

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3.4 Field of Application
3.4.1 Tank
a) Single-walled horizontal (underground or aboveground) cylindrical
tanks with leak protection lining (LAK) or jacket (LUM) and suction
line leading to the low point
Usage limits: None for density and diameter
b) Double-walled horizontal cylindrical (underground or aboveground)
tanks (e.g., DIN 6608-2, 6616, or DIN EN 12 285-1-2)
- Same as a), but with no suction line to low point
- Same as c), but with no suction line to low point
- Same as d), but with no suction line to low point
Usage limits:
Density of
the stored
material
[kg/dm3]
Hmax.(tank height) [m]
230 255 330 410 500 570
0.8 2.6 2.9 3.8 4.8 6.0 6.9
0.9 2.3 2.6 3.4 4.3 5.3 6.1
1.0 2.0 2.3 3.1 3.9 4.8 5.5
1.1 1.9 2.1 2.8 3.5 4.4 5.0
1.2 1.7 1.9 2.6 3.2 4.0 4.6
1.3 1.6 1.8 2.4 3.0 3.7 4.2
1.4 1.5 1.6 2.2 2.8 3.4 3.9
1.5 1.4 1.5 2.0 2.6 3.2 3.7
1.6 1.3 1.4 1.9 2.4 3.0 3.4
1.7 1.2 1.4 1.8 2.3 2.8 3.2
1.8 1.1 1.3 1.7 2.2 2.7 3.1
1.9 1.1 1.2 1.6 2.0 2.5 2.9
A minimum of density 1 is needed for underground systems.
c) Double-walled (or single-walled with leak protection lining or jack-
et) vertical cylindrical tanks or troughs with a dished bottom (un-
derground or aboveground) with a suction line leading to the low
point (DIN 6618-2: 1989)
Technical Data

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Usage limits:
Diameter
[mm]
Height
[mm]
Max. density of the stored material
[kg/dm3]
34 230 255 330 to 570
1600 2820 1.9 1.9 1.9 1.9
3740 1.6 1.9 1.9 1.9
5350 1.6 1.9 1.9 1.9
6960 1.6 1.9 1.9 1.9
2000 5400 1.4 1.9 1.9 1.9
6960 1.4 1.9 1.9 1.9
8540 1.4 1.9 1.9 1.9
2500 6665 1.0 1.9 1.9 1.9
8800 1.0 1.9 1.9 1.9
2900 8400 0.9 1.9 1.9 1.9
9585 0.9 1.9 1.9 1.9
12,750 0.8 1.2 1.2 1.6
15,950 - 1.0 1.0 1.2
d) Rectangular or cylindrical tanks or troughs with a flat bottom (dou-
ble-walled or with leak detection lining or leak detection jacket)
with a suction line to low point
Density of the
stored mate-
rial
[kg/dm3]
Hmax.[m]
34 230 255 330 410 500 570
0.8 7.5 17.3 19.1 23.4 23.8 24.5 24.2
0.9 6.6 15.3 17.0 20.8 21.1 21.8 21.5
1.0 6.0 13.8 15.3 18.7 19.0 19.6 19.4
1.1 5.4 12.6 13.9 17.0 17.3 17.8 17.6
1.2 5.0 11.5 12.8 15.6 15.8 16.4 16.2
1.3 4.6 10.6 11.8 14.4 14.6 15.1 14.9
1.4 4.3 9.9 10.9 13.4 13.6 14.0 13.8
1.5 4.0 9.2 10.2 12.5 12.7 13.1 12.9
1.6 3.7 8.6 9.6 11.7 11.9 12.3 12.1
1.7 3.5 8.1 9.0 11.0 11.2 11.5 11.4
1.8 3.3 7.7 8.5 10.4 10.6 10.9 10.8
1.9 3.1 7.3 8.1 9.8 10.0 10.3 10.2
Technical Data

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e) Vertical cylindrical tanks with double-layered floor made of metal
(e.g., according to DIN 4119 or EN 14015)
- As above, but with leak protection lining (stiff or flexible)
- Vertical cylindrical tanks made of plastic with double-layered
floor
Usage limits: None for density and diameter
f) Tanks according to a) to d) that operate with an inner overlay
pressure of up to 25 bar
Usage limits: in line with the aforementioned points using a type
VL .. MV
3.4.2 Monitorable fluids
Liquids hazardous to water with a flash point of over 60°C (for Ger-
many: 55°C in accordance with TRBS and TRGS ), e.g., heating oil,
diesel, acids, and alkalis.
The following also applies:
oThe materials used must be resistant to the liquids being moni-
tored.
oLiquids hazardous to water must not develop explosive vapor-air
mixtures (not even those that can arise through stored/conveyed
liquid in contact with air, humidity, condensation, or the materials
used).
Technical Data

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4. Design and Function
4.1 Design
4.1.1 Plastic housing interior view
Interior view with:
01 Signal lamp “Alarm”, red
01.2 Signal lamp “Alarm 2”
09 Signal lamp “Operation”, green
20 Three-way valve, suction line
21 Three-way valve, measuring line
36 “Commissioning” key
60 Vacuum pump
61 Check valve with filter
69 Buzzer
71 “Mute” button
76 Main board
102 Pressure sensor
61
102
20
21
60
76
Design and Function
09
01
01.2
71
36
69

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4.1.2 Stainless steel housing internal view
Interior view with:
20 Three-way valve, suction line
21 Three-way valve, measuring line
60 Vacuum pump
61 Check valve with filter
69 Buzzer
71 “Mute” button
75 Display board
76 Main board
102 Pressure sensor
139 Keypad (on front)
144 Temperature switch, frost protection
75
20
21
102
144
60
139
76
61
69
Design and Function

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4.2 Normal Operating Condition
The vacuum leak detector is connected to the interstitial space via
suction, measuring, and connection lines. The vacuum generated by
the pump is measured and controlled by a pressure sensor.
When the operating vacuum is reached (Pump OFF), the pump shuts
off. The vacuum slowly drops due to slight, unavoidable leaks in the
leak detector system. When the Pump ON switching value is reached,
the pump turns on and the interstitial space is evacuated until the op-
erating vacuum is reached (Pump OFF).
In normal operating condition, the vacuum swings between the Pump
OFF and Pump ON switching values, with short periods when the
pump is run and longer standstills, depending on the tightness and
temperature fluctuations of the entire unit.
4.3 Air Leaks
If an air leak occurs (in the outer or inner wall, above the liquid level),
the vacuum pump switches on to restore the operating vacuum. If the
leak causes the incoming air to exceed the pump’s capacity limit, the
pump remains on continuously.
Increasing leak rates lead to a further decrease in pressure (with the
pump running) until the Alarm ON switching value is reached. This
triggers the visual and audible alarms.
4.4 Liquid Leaks
In case of a liquid leak, the liquid enters the interstitial space and col-
lects in the low point of the interstitial space.
The incoming liquid decreases the vacuum, which causes the pump
to turn on and evacuate the interstitial space(s) until the operating
vacuum is reached. The process repeats itself until the liquid stop
valve in the suction line closes.
Because of the vacuum that still exists on the measuring line side,
additional stored material or water is sucked into the interstitial space,
the measuring line, and, if applicable, into a pressure compensation
vessel. This causes the vacuum to drop until the “Alarm ON” pressure
is reached. This triggers the visual and audible alarms.
Comment: It is also an option to use a liquid sensor in conjunction
with a solenoid valve instead of the liquid stop valve. The liquid alarm
is then triggered when the sensor comes into contact with liquid.
4.5 Pressure increase above atmospheric pressure in the interstitial space when using a
leak detector VL .. with solenoid valve (MV)
If a pressure increase of more than 50 mbar above atmospheric pres-
sure occurs in the interstitial space, the solenoid valve in the suction
and/or measuring line is closed and the pump switches off.
The pressure increase is indicated visually and acoustically (pressure
build-up alarm).
Design and Function


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4.6 Displays and Controls
4.6.1 Display
4.6.2 “Turn off audible alarm signal” function
Briefly press “Mute” button once; audible signal turns off, and the red
LED flashes.
Pressing the button again will turn the audible signal on.
This function is not available during normal operating conditions and
malfunctions.
4.6.3 “Testing the optical and audible alarm signal” function
Press and hold the “Mute” button (for about 10 seconds). The alarm
will be triggered until the key is released.
This inquiry is only possible if the pressure in the system has exceed-
ed the “Alarm OFF” pressure.
2(Flashing) is active for the acknowledged external signal.
3The “Sound off” key does not have a function, which means the audible signal cannot be turned off.
Signal
lamps
Operating condi- tion Alarm, vacuum below “ Alarm ON” Probe alarm Solenoid valve malfunction Pressure build- up alarm Device malfunc- tion
OPERA-
TION:
green
ON ON ON ON ON ON
ALARM:
red OFF ON
(flashing)2OFF
ON
(flash-
ing)
ON
(flash-
ing)
ON3
ALARM 2:
yellow OFF OFF
ON
(flash-
ing)
ON Flashing OFF
Design and Function

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4.6.4 “Tightness inquiry” function
Press and hold the “Mute” button until the signal lamp is flashing rap-
idly, then release it. The display (103) will show a tightness value and
the same value will be indicated by the number of “Alarm” signal lamp
flashes.
This display disappears after 10 seconds and the current vacuum in
the system is displayed again.
For the tightness inquiry function, the leak detector must have per-
formed at least 1 automatic refilling interval in normal operating condi-
tions (i.e., without external filling/evacuation, e.g., by an assembly
pump) to achieve a valid statement.
This inquiry is recommended before performing a regular functional
check of a leak detector. In this way, it is possible to estimate imme-
diately whether it is necessary to look for leaks.
Number of flash signals Assessment of tightness
0 Very tight
1 to 3 Tight
4 to 6 Sufficiently tight
7 to 8 Maintenance recommended
9 to 10 Maintenance urgently recommended
The smaller the above value, the tighter the system. The significance
of this value also depends on temperature fluctuations and should
thus be considered a reference point.
Design and Function
(
103
)

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5. Mounting the System
5.1 Basic Instructions
oPrior to commencing work, the documentation must be read and
understood. In case of ambiguities, please ask the manufacturer.
oObserve the approvals of the manufacturer for the tank and the in-
terstitial space.
oThe safety instructions in this documentation must be adhered to.
oOnly qualified service companies may be used for assembly and
commissioning4.
oLead-throughs for pneumatic and electric connection lines must be
sealed gas-tight.
oComply with relevant regulations regarding electric installation and
regulations for prevention of accidents.
oPneumatic connections, connection lines, and fittings must with-
stand the excess pressure that may occur over the entire tempera-
ture range.
oBefore entering inspection chambers, the oxygen content must be
tested and the inspection chamber flushed if necessary.
oWhen using metallic connection lines, proper equipotential bond-
ing must be ensured; alternatively, electrical isolators must be
used.
5.2 Assembly of the Leak Detector
oWall mounting using the supplied mounting material.
oOutside of the potentially explosive area (zone 1 or 2), also applies
to the connection lines and interstitial space.
oPlastic housing: In a dry room
Stainless steel housing: Outdoors, without additional protective
box.
oTo avoid excessive heating, the leak detector must not be installed
directly next to a heat source.
The ambient temperature must not exceed 60°C; appropriate
measures may need to be taken (e.g., installation of a roof to pro-
tect against sunlight).
oVentilation systems must be kept clear.
oDo not mount in access or inspection chambers.
4For Germany: Specialist service companies as per German water legislation that have documented qualifi-
cations to install leak detection systems.
Mounting

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5.3 Pneumatic Connection Lines
5.3.1 Requirements
oAt least 6 mm inside clearance
oResistant to the stored or conveyed product
oPressure and vacuum-resistant across the entire temperature
range
oThe full cross section must be maintained (not bent)
oColor coding: Measuring line: RED
Suction line: WHITE or CLEAR
Exhaust: GREEN
oThe lines between the interstitial space and leak detector must not
exceed 50 m in length. If the distance is greater than this, a larger
cross section must be used.
oCondensate traps must be installed at all low points of the connec-
tion lines.
oAssemble liquid stop valve in the suction line (generally included in
the assembly kit).
5.3.2 Exhaust
oThe exhaust line usually feeds to the tank ventilation.
oExceptions to the return of the exhaust to the tank ventilation:
Tanks with interior overlay pressure, tanks according to DIN 4119
or EN 14015 with double-layered floor, or comparable:
The exhaust line can lead outside to a safe5area: Fit a condensate
trap and a liquid stop valve in the exhaust line.
oCaution: An exhaust line which ends outdoors must not in any cir-
cumstances be used to detect leaks (e.g., by “sniffing”). Attach
warning signs if necessary.
5.4 Completing Pneumatic Connections
5.4.1 Assembling the connection to the tank’s interstitial space
(1) Generally according to the tank manufacturer’s specifications.
(2) SGB offers assembly kits with the various connection possibili-
ties.
5.4.2 Between leak detector and interstitial space
(1) Select and install suitable pipe.
(2) During installation of the pipe, ensure that it is protected against
damage when the access chamber is entered.
(3) Complete the relevant connection (according to the illustrations in
the following images).
5Among other things, not accessible to public transport/persons
Mounting
