SGB VLR Series Operator's manual

Documentation
Vacuum leak detector VLR
in 100–240 V AC and 24 V DC
Read instructions prior to commencing any work
As of: 05/2020
Item no.: 605 342

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Overview of the Design Variations
Vacuum leak detectors VL(R) are available in different versions that are described more precisely by
the letters attached to them. The levels of availability and the possible combinations depend on the
device. Please contact our sales team. Phone [phone], email [email protected]
VL(R) .. E FA P M MV LG LE S Si T
“Tightness alarm”
“Service Indication”: (LED) display
with variably adjustable service peri-
ods
“Service display”: Integrated service dis-
play with fixed 12-month interval
“LOD Ethernet”: Leak detector online di-
agnosis remote monitoring with Ethernet
module
“LOD GSM module”: Leak detector online diag-
nosis remote monitoring with wireless module
“Solenoid valve” (MV): An MV with monitored
function can be connected for applications with
high pressure in the inner pipe.
“Manometer”: The leak detector is equipped with a digi-
tal pressure indicator in the housing cover.
“Protected”: Leak detector version in a weather-protected
housing
“Filling level indicator” (FA): An electronic filling level indica-
tor is integrated in the leak detector
“Enhanced functions”: This version provides the option of connect-
ing 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 pipes” (R). The leak detector operates with
negative pressure toward the atmosphere.
Variations/Options

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Table of Contents
1.Gener ........................................................................................... 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 ...............................................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................................................................ 13
4.1Design ................................................................................... 13
4.2Normal Operating Conditions ................................................ 15
4.3Air Leaks ............................................................................... 15
4.4Liquid Leaks .......................................................................... 15
4.5Pressure Increase Above Atmospheric Pressure in the
Interstitial Space When Using a Leak Detector
VLR .. with Solenoid Valve (MV) ........................................... 15
4.6Displays and Controls ...........................................................16
5.Mounting the System ............................................................... 18
5.1Basic Instructions .................................................................. 18
5.2Assembly of the Leak Detector .............................................18
5.3Pneumatic Connection Lines................................................. 19
5.4Completing Pneumatic Connections ..................................... 20
5.5Electrical Cables.................................................................... 21
5.6Electrical Wiring Diagram ...................................................... 22
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
8.Malfunction (Alarm).................................................................. 39
8.1Alarm Description .................................................................. 39
8.2Malfunction ............................................................................ 39
8.3How to Behave ...................................................................... 39
Contents

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9.Spare Parts................................................................................40
10.Accessories.............................................................................40
11.Appendix .................................................................................41
11.1Dimension and drilling illustration ..........................................41
11.2Declaration of Conformity ......................................................43
11.3Declaration of Performance (DoP).........................................44
11.4Declaration of Compliance of the Manufacturer (ÜHP) .........44
Contents

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1. General
1.1 Information
These instructions provide important notes on using the leak detector
VLR … 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 VLR .. 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.
The serial number of the leak detector must be stated.
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
No liability is accepted for delivery parts that wear or are consumed
prematurely due to their material properties or application (e.g.,
pumps, valves, seals, etc.). We do not assume responsibility for cor-
rosion damage due to a humid installation site.
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 pipes 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
Conveyed product needs to have a flash point of over 60°C (for
Germany > 55°C in accordance with TRBS and TRGS), i.e., the
conveyed product 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 VLR .. is used in the commercial sector. The oper-
ating company is therefore subject to statutory occupational safety
obligations.
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
relevant training with SGB, through SGB, or through its authorized
representative.
National guidelines must be adhered to.
For Germany: Technical service qualification for mounting, 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 inad-
equate qualifica-
tion
WARNING!
Danger in case of
incomplete doc-
umentation

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2.4 Personal Protective Equipment
Personal protective equipment must be worn during work.
oWear the necessary protective equipment for the work in question
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 open 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 in order to complete the
mounting process.
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 11.1
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 (feed pressure)
with solenoid valve > 5 ≤25 bar (feed pressure)
with solenoid valve and
additional pressure switch > 25 bar ≤90 bar (feed pressure)
3.2 Electrical Data
Power supply 100 to 240 V AC, 50/60 Hz
or: 24 V DC
Power input 50 W (incl. heating)
Terminals 5, 6, external signal: max: 24 V DC; max. 300 mA
Terminals 11–13, potential free: DC ≤25 W or AC ≤50 VA
Terminals 17–19, 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
IS* given for
34 - 34 mbar - 120 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.
Overpressure alarm (VLR .. with solenoid valve) at +50 mbar
* IS = interstitial space
Technical Data

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3.4 Field of Application
3.4.1 Pipelines/tubes
In factory or on-site construction
oSuction lines: The alarm vacuum shall be at least 30 mbar higher
than the max underpressure in the inner pipe at the high point of
the interstitial space
oPressure lines with feed pressures of up to 5 bar: Version VLR 330
to VLR 570
oPressure lines with feed pressures of up to 25 bar:
Version VLR 330 to VLR 570, each with solenoid valve
oPressure lines with feed pressures of up to 90 bar:
Version VLR 330 to VLR 570 with solenoid valve and only in con-
junction with an additional pressure switch
oIn particular applications (single pipe, downward gradient to the
low point of the interstitial space to which the suction line is also
connected), version VLR 34 can also be used (no Hmax).
oFor Germany: with proof of usability from construction authority
Usage limits:
Density of the stored
product
[kg/dm3] 330 410 500 570
0.8 3.8 4.8 6.0 6.9
0.9 3.4 4.3 5.3 6.1
1.0 3.1 3.9 4.8 5.5
1.1 2.8 3.5 4.4 5.0
1.2 2.6 3.2 4.0 4.6
1.3 2.4 3.0 3.7 4.2
1.4 2.2 2.8 3.4 3.9
1.5 2.0 2.6 3.2 3.7
1.6 1.9 2.4 3.0 3.4
1.7 1.8 2.3 2.8 3.2
1.8 1.7 2.2 2.7 3.1
1.9 1.6 2.0 2.5 2.9
A minimum of density 1 is needed for underground systems.
Technical Data

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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).
oIf different water-polluting liquids are conveyed in individual pipe-
lines and monitored with a leak detector, these liquids or their mix-
ing must not have any hazardous effects on one another or cause
any chemical reactions.
Technical Data

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

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4.1.2 Stainless steel housing internal view
Interior view with:
20 Three-way valve in the suction line
21 Three-way valve in the measuring line
60 Vacuum pump
61 Check valve with filter
69 Buzzer
75 Display board
76 Main board
102 Pressure sensor
139 Keypad
140 Contact for serial data transfer
141 Keypad terminal strip
144 Temperature switch, frost protection
75
20
21
144
60
139
76
61
69
102
140
141
Design and Function

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4.2 Normal Operating Conditions
The vacuum leak detector is connected to the interstitial space via
suction, measuring, and connection line(s). 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 conditions, 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 the event of a liquid leak, the liquid enters the interstitial space and
collects 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 or conveyed product or water is sucked into the in-
terstitial 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 sole-
noid 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 VLR .. 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 connec-
tion line is closed and the pump switches off.
Design and Function


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The pressure increase is indicated visually and acoustically (pressure
build-up alarm).
For the version up to 90 bar (additional pressure switch and solenoid
valve), the additional pressure switch is actuated in the case of a fast
pressure increase, which immediately closes the solenoid valve to
protect the leak detector from inadmissably high pressures. The pres-
sure build-up alarm is triggered; if the additional pressure switch is
connected via the probe contacts, the probe alarm is also shown.
4.6 Displays and Controls
4.6.1 Display
4.6.2 Function “Turn off audible alarm signal”
Briefly press “Sound off” key once; audible signal turns off, and the
red LED flashes.
Pressing the key again will turn the audible signal on.
This function is not available during normal operating conditions and
malfunctions.
1(Flashing) is active for the acknowledged external signal.
2The “Sound off” key does not have a function, which means the audible signal cannot be turned off.
Indicator
light
Operating condition Alarm vacuum below “AlarmON” Probe alarm Solenoid valve mal- function
Pressure build-up
alarm
Malfunction Tightness alarm T
OPERA-
TION:
green ON ON ON ON ON ON ON
ALARM:
red OFF
ON
(Flash-
ing)1
OFF
ON
(Flash-
ing)
ON
(Flash-
ing)
ON2
ON
(Flash-
ing)1
ALARM 2:
yellow OFF OFF
ON
(Flash-
ing)
ON Flash-
ing OFF
ON
(Flash
es
twice)
Design and Function

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4.6.3 “Testing the optical and audible alarm signal” function
Press and hold the “Sound off” key (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.
4.6.4 “Tightness inquiry” function
Press and hold the “Sound off” key until the signal lamp is flashing
rapidly, 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 pipeline and the
interstitial space.
oThe safety instructions in this documentation must be adhered to.
oOnly qualified service companies may be used for assembly and
commissioning3.
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.
3For 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 can lead outside to a safe4area:
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.
5.3.3 Several pipeline interstitial spaces are connected in parallel
oLay connection lines at a downward angle to the interstitial space
or the manifold. If there are low points in the connection lines and
lines are laid outdoors as well, install condensate traps at all low
points.
oLay suction and measuring lines at a downward angle to the mani-
fold. If this is not possible, place condensate traps at all low points.
oConnect a liquid stop valve to each connection line to the intersti-
tial space, against the valve direction.
This prevents leaking liquids from entering the interstitial spaces of
the other pipelines.
oIf shut-off cocks are installed in the connection lines, then they
should be sealable in the open position.
4Among other things, not accessible to public transport/persons
Mounting

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oFor applications with pressure compensation vessel (see 5.7.4 and
5.7.5):
Length of the measuring line from the pressure compensation ves-
sel (V=0.1 l)5:
Type 330: Lmax 16 m
Type 410 Lmax 12 m
Type 500 Lmax 10 m
Type 570 Lmax 8 m
CAUTION: The bottom edge of the pressure compensation vessel
must not be lower than the node point; the upper edge of the pres-
sure compensation vessel must not end more than 30 cm above
the node point.
For each 10 ml of the condensate trap(s) used in the measuring
line between the pressure compensation vessel and leak detector,
Lmax is reduced by 0.5 m
oOR (alternatively to the pressure compensation vessel)
50% of the overall length of the measuring line must be laid with a
0.5 to 1% downward gradient to the node point. Lmin = 0.5 x total
length of the measuring line.
5.3.4 Several pipeline interstitial spaces are connected in series
The liquid stop valves installed against the direction of flow (27*) pre-
vent the other interstitial spaces from becoming filled with liquid in the
event of a leak in a pipeline.
The interstitial space volumes of the connected pipes must meet the
following conditions:
3∙VIS 1 > VIS 1 + VIS 2 + VIS 3 + VIS 4 and
3∙VIS 2 > VIS 2 + VIS 3 + VIS 4, etc.
VIS (number) is the volume of the respective interstitial space. No. 1 is the
interstitial space the suction line is connected to (see 5.7.6)
5.4 Completing Pneumatic Connections
5.4.1 Assembling the connection to the pipeline interstitial space or test valves
(1) Generally according to the specifications provided by the manu-
facturer of the pipeline/interstitial space.
(2) If Schrader valves are used, please proceed as follows:
oUnscrew protective cap
oRe-tighten lock nut
oUnscrew valve insert and stick next to the connection with ad-
hesive tape. (As evidence of disassembly)
oScrew connection to the interstitial space or test valve and fas-
ten finger-tight
oIf necessary, further tighten with suitable pliers
5If this volume is multiplied, Lmax is multiplied in the same way.
Mounting