SGB VLX Ex Series Operator's manual

Vacuum leak detector
VLX ../A-Ex
Documentation VLX ../A-Ex
SGB GMBH
Hofstraße 10
57076 Siegen
GERMANY
Art. No.: 602 602
Issue: 07/2018

VACUUM LEAK DETECTOR VLX ../A-Ex
- GI-1 - 26/08/2016
Table of contents for documentation
1 Technical description of VLX ../A-Ex 17 pages
2 Drawings for the technical description of VLX ../A-Ex 21 pages
3 Appendix to the technical description of VLX ../A-Ex 5 pages
4 Dimension and drilling illustration 1 page
5 Worksheet: Installation of pneumatic connections 2 pages
6 EU declaration of conformity 1 page
7 Declaration of performance (DoP) 2 pages
8 Certification TÜV Nord 2 pages
9 Warranty 1 page

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Table of Contents Page
1 Subject 2
2 Operative Range 2
2.1 Requirements for the Interstitial Spaces 2
2.2 Containers up to 0.5 bar overlay pressure 2
2.3 Pipes/Hoses 3
2.4 Permissible overlay pressures/conveyance pressures 3
2.5 Stored/conveyed product 3
2.6 Resistance to Materials 3
3 Function Description 4
3.1 Normal Operation 4
3.2 Air Leaks 4
3.3 Liquid Leaks 4
3.4 Switch Values of the Leak Detector 4
4 Installation Instructions 5
4.1 General Notes 5
4.2 Personal Protective Equipment 5
4.3 Installation of the Leak Detector 5
4.4 Installation of the Pneumatic Connecting Lines 6
4.5 Installation of the Electric Connecting Lines 8
4.6 Electrical Connection 8
4.7 Additional Notes for Underground Tanks/Pipes 9
4.8 Installation Examples 10
5 Start Up 10
6 Operating Instructions 11
6.1 General Notes 11
6.2 Intended Use 11
6.3 Maintenance 12
6.4 Function Testing 12
6.5 Alarms 16
7 Removal 17
8 Marking 17
9 Index Used 17
Drawings:
Position of three-way valves P –096 000
Position of valves in suction- and measuring lines (V4A Version) P –098 000
Interior view of magnetic valve version I –000 000
Installation examples (schematic diagrams) for tanks A-01 to H/I/J-02
Installation examples (schematic diagrams) for pipes L/M–01 to L/M–03
Testing device P –115 392-a
Testing device (V4A Version) P –115 392-b
Wiring diagram (VLX ../A-Ex and VLX ../ME) SL –854 400-25
Wiring diagram (VLX ../A-Ex-MV and VLX ../ME-MV) SL –854 500
Wiring diagram (VLX ../A-MV-Ex with floating probe) SL –854 510
Wiring diagram (VLX ../A-MV-Ex with sensor) SL –854 520
Wiring diagram (VLX ../A-Ex and VLX ../ZME) SL –854 600
Appendix:
A VLX ../A-EX to tanks with leak detection liquid in the interstitial space A-1
E Usage limits for VLX ../A-Ex E-1
TD Technical Data TD-1
LS Supplement Leakage Sensor LS-1

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1. Subject
Vacuum leak detectors of Type VLX ../A-Ex in partially explosion-proof models as part of a leak
detection system.
2. Operative Range
2.1. Requirements for the Interstitial Spaces
Vacuum-resistant with respect to the operating vacuum of the leak detector, even with
temperature fluctuations.
Ensuring the suitability of the interstitial space as part of a leak detection system (e.g. DIN
standards, applicability certificates, suitability of use declarations etc.).
No leak-detector liquid in the interstitial space (if there is liquid, see Appendix A)
Tanks listed at 2.2 must fulfill the above requirements.
2.2. Tanks up to 0.5 bar overlay pressure
Group
Tank design
Instal-
lation
example
Suitable
Leak Detector
Type
Usage limits
A
Single-walled horizontal (underground or
aboveground) cylindrical tanks with leak
detection lining or jacketing and suction line
leading to the low point
A –01
VLX 34/A-Ex
VLX 330/A-Ex
None for
density and
diameter
B
Same as A, but no suction line to the low point
B/C–01
VLX 330/A-Ex
App. E, no. E.1
C
Double-walled horizontal cylindrical (underground
or aboveground) tanks
D
Double-walled (or single-walled with leak
detection lining or jacketing) vertical cylindrical
tanks or troughs with a dished bottom
(underground or aboveground) with a suction line
leading to the low point
D–01
VLX 34/A-Ex
VLX 330/A-Ex
App. E, no. E.3
E
Same as D, but no suction line to the low point
E –01
VLX 330/A-Ex
App. E, no. E.1
F
Rectangular or cylindrical tanks or troughs with a
flat bottom (double-walled or with leak detection
lining or leak detection jacket) with a suction line
to the low point
F–01
VLX 34/A-Ex
VLX 330/A-Ex
App. E, no. E.2
G
Same as F, but no suction line to the low point
G–01
VLX 330/A-Ex
App. E, no. E.1
H
Standing cylindrical tanks with double bottom
made of metal (e.g. according to DIN 4119)
H/I/J–01
H/I/J–02
VLX 330/A-Ex
None regarding
tank height and
stored product
density
I
Same as H, but with leak detection lining (rigid or
flexible)
J
Standing cylindrical tanks made of plastic with
double bottom.

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2.3. Pipes
1
/Hoses
Group
Pipe
Installation
example
Suitable Leak
Detector Type
Usage limits
L
Pipes made at the factory or on-site of metal or
plastic with general building site approval or with
acceptance as part of an individual determination
by the responsible authority.
L/M–01
L/M–02
L/M–03
VLX 330/A-Ex
Up to 10 bar
conveyor
pressure
M
Double-walled hoses made at the factory or on-
site of metal or plastic with general building site
approval or with acceptance as part of an
individual determination by the responsible
authority.
2.4. Permissible overlay pressures/conveyance pressures
VLX /A-Ex Designs as listed under 2.2 and 2.3 with overlay pressures/conveyance
pressures up to 10 bar.
VLX ../A-MV-Ex: Designs as listed under 2.2 and 2.3 with overlay pressures/conveyance
pressures up to 25 bar.
2.5. Stored/conveyed product
Water-polluting liquids, the (possible) explosive vapor-air mixture (even those which stem from
the stored liquid combined with air, humidity, condensation or the materials with which the liquid
comes into contact) must be classified in gas group II A to II B3, as well as temperature code T1
to T3(T4) such as gasoline, for example.
If different water-polluting liquids are conveyed in individual pipes and monitored with one leak
detector, these liquids must not have any hazardous effects on one another or cause any
chemical reactions.
2.6. Resistance to Materials
For VLX ../A-Ex leak detectors, material MS 58 or (1.4301, 1.4306, 1.4541)
2
or 1.4571
3
, as well
as the material used for the connecting lines, must be sufficiently resistant to the stored
product
4
.
1
Double-walled armatures may be integrated into the pipes. Double-walled armatures can also be monitored for
themselves with this leak detector; use corresponding installation examples for pipes.
2
See DIN 6601, center section
3
See DIN 6601, right section
4
Sufficient means that the physical properties are not adversely affected; discoloration is acceptable.

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3. Function Description
3.1. Normal Operation
The vacuum leak detector is connected with the interstitial space via suction-, measuring- and
connection line(s). The vacuum generated by the pump is measured and controlled by a
vacuum switch.
When the operating vacuum is reached (Pump OFF), the pump shuts off. The vacuum drops off
slowly due to slight, unavoidable leaks in the leak detector system. When the Pump ON switch
value is reached, the pump turns on and the interstitial space is evacuated until the operating
vacuum is reached (Pump OFF).
In normal operation, the vacuum swings between the Pump OFF and Pump ON switch values,
with short periods when the pump is run and longer standstills, depending on the tightness and
temperature fluctuations of the leak detection system.
3.2. 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 increase in pressure (with the pump running) until the
Alarm ON switch value is reached. This triggers the visual and audible alarms.
In Version VLX ../A-MV (called MV version in the following), the magnetic valve in the suction
line is also closed.
3.3. Liquid Leaks
In case 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 leaked liquid is
sucked into the interstitial space, the measuring line and, if applicable, into a pressure-
compensating vessel. This causes the vacuum to drop until the “Alarm ON” pressure is
reached. This triggers the visual and audible alarms.
In the MV version, the magnetic valve i the suction line is also closed.
3.4. Switch Values of the Leak Detector
Type
Alarm ON
Pump OFF
Used in Group:
VLX 34/A-Ex
60 25
100 25
A/D/F
VLX 330/A-Ex
370 40
500 40
A/B/C/D/E/F/G/H/I/J/L/M
The measured switch value for “Alarm OFF” must be less than the measured switch value for “Pump
OFF”.
The measured value for “Pump ON” must be greater than the measured value for “Alarm ON”.

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4. Installation Instructions
4.1. General Notes
(1) Observe the approvals of the manufacturer for the tank/pipe and the interstitial space.
(2) Only qualified service companies may be used for installation and start up
5
.
(3) Comply with relevant regulations regarding electric installation
6
, (e.g. EN 60 079-14)
explosion protection
7
(e.g. EN 60 079-17) und safety.
(4) Explosion protection requirements must be satisfied (where necessary), such as laws on
the basis of the European Directive 1999/92/EG and/or other applicable codes.
(5) Pneumatic connections, connecting lines and fittings must be designed to at least PN 10
and/or PN25 for the entire temperature range.
(6) Before entering inspection chambers, the oxygen content must be tested and the
inspection chambers must be rinsed.
(7) Conduits for pneumatic and electric connecting lines, through which the explosion
atmosphere can carry over, must be sealed gas-tight.
(8) When using metallic connection lines, you must make sure that the mains earth is
connected to the same potential as the tank/pipe being monitored.
4.2. Personal Protective Equipment
The parts listed here refer in particular to safety when working with systems that may be subject
to risk of explosion.
If work is performed in areas in which an explosive atmosphere may be expected, the minimum
required equipment is as follows:
Suitable clothing (risk of electrostatic charge).
Suitable tools (e.g., per EN 1127).
Suitable combustible gas indicator calibrated to the existing vapor-air mixture (work should
be performed only at a concentration of 50% below the lower explosion limit)
8
.
Measuring equipment to determine the oxygen content of the air (Ex/O-Meter)
4.3. Installation of the Leak Detector
(1) The VLX leak detector consists of a indicating device (VLX ME, VLX ME-MV) or central
indicating device (VLX ZME) and a leak detector (VLX ../A-Ex , VLX ../A-MV-Ex).
(2) The indicating device fits the term “leak indicating device” and the “leak detector”.
(3) All housings are designed for installation on a wall.
5
For Germany: Specialist services per water rights, which have documented qualifications to install leak detection
systems including documented qualifications for working in hazardous areas (Ex-areas).
For Europe: Authorization from the manufacturer.
6
For Germany: e.g., VDE regulations, regulations of the electrical supply companies.
7
For Germany: e.g., ElexV, GSiG.
8
Other countries’ regulations may give different percentages.

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4.3.1 Installation of the leak detector
(4) Outside and inside the hazardous location (zone 1), in the open air, without any more
protective boxes.
Chose a mounting place, where the ventilation in the housing (by convection) between the
flange plate (be distant to the housing) and the vent opening is not being effected.
If the protection box should nevertheless be necessary for operational reasons, the
protective box must be ventilated in a way that the ventilation as mentioned above is not
effected.
(5) If the leak detector is installed in an enclosed space (e.g. room), it must be well ventilated.
The operator shall apply EN 60 079-10 / EN 13237 as a basis for evaluation.
(6) To avoid excessive heating, the leak detector must not be installed directly next to a heat
source.
The ambient temperature must not exceed 40°C; appropriate measures must be taken.
(e.g. installation of a roof to protect against sunlight).
(7) Not in manhole pits or inspection chambers.
4.3.2 Assembly of the indicating device VLX ME / VLX ZME / VLX ME-MV
(4) NOT in potentially explosive areas.
(5) Inside a closed, dry area.
Alternatively: Installation in suitable protective boxes, use an additional external signal or
assignment of the potential free contacts to alarm transmission.
(6) Do not install directly next to a strong heat source.
(7) At least 1 m away from the leak detector.
4.4. Installation of the Pneumatic Connecting Lines
(1) Strong, metallic pipes must be used for the connecting lines (e.g. copper pipes). Plastic
pipes with sufficient pressure resistance (over the entire temperature range) may also be
used if the interstitial space is NOT zone 0.
Conduits for connecting lines through which the explosion atmosphere can carry over must
be sealed gas-tight.
(2) Inside clearance at least 6 mm.
(3) Resistant to the stored product.
(4) Color coding: Measuring line RED; suction line: WHITE or CLEAR; exhaust GREEN:
(5) The full cross section must be maintained.
(6) The 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. .
For the exhaust line there are different requirements, see sec. 4.4.1.
(7) Condensate traps must be installed at all low points of the connecting lines.
(8) Install a liquid stop valve in the suction line.
(9) If liquids are being stored or conveyed that require compliance with explosion protection,
there are suitable flame arresters to be installed at the entry to the interstitial space.

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(10) Leak detector side flame arresters:
Are necessary, when either the suction line or the exhaust line (or both) are connected
to zone 0.
Are not necessary, if both the suction line and the exhaust line are NOT connected to
zone 0.
(11) For applications with pressure-compensating vessel (see drawing L/M-01 to L/M-03):
Length of the measuring line from the pressure-compensating vessel (V=0.1 l)
9
:
Type 330:Lmax 8 m
For every 10 ml of the condensate trap(s) used in the measuring line between the
pressure-compensating vessel and leak detector, Lmax is reduced by 0.4 m.
Alternatively: 50 % of the overall length of the measuring line must be laid horizontally, or
with a 0.5 to 1 % gradient to the node point. Lmin = 0,5 x total length of the measuring line
(compare with L/M-01 top drawing).
(12) When using the V4A version, as a rule, stop cocks should be provided on the interstitial
space side.
4.4.1 Installation of the exhaust line
(1) The following lengths may not be exceeded for the exhaust line:
Pipe with 6 mm inside clearance: 50 m (F 501 for explosion group IIA + F 502)
If these lengths are not sufficient, the manufacturer must be consulted.
(2) The exhaust line is generally routed to the tank vent, in which case an explosion protection
device must be installed on the tank vent side.
Exceptions:
Tanks with interior overlay pressure, tanks according to DIN 4119 with double-layered floor,
or comparable:
A) The exhaust line can lead outside to a safe
10
area, outside of the explosion area:
Provide a condensate trap and liquid stop valve in the exhaust. The area within 1 m
diameter of the end of the exhaust is considered as having zone 1 conditions; attach a
warning sign if necessary.
B) The exhaust ends in zone 1 (e.g. remote fill chamber or collection space):
An explosion protection device
11
must be provided at the end of the exhaust line.
Condensate traps must be provided at low points; a liquid stop valve is not required if
the end of the exhaust is in an area which is made liquid-tight according to water
protection laws.
(3) Caution: An exhaust line which ends outdoors must not in any circumstances be used to
detect leaks (e.g. by “sniffing”). Attach warning signs if necessary.
4.4.2 Connecting several pipe interstitial spaces parallel to a leak detector via a
distributor (see L/M 02)
9
If this volume is multiplied, Lmax.is multiplied in the same way.
10
Amongst other things, not accessible to the public traffic/people
11
The explosion protection device is not required if the exhaust is routed so that it is frost proof, and it can be
guaranteed that the exhaust will not become kinked or clogged.

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ON
OFF
(1) Lay connecting lines at a downward angle to the interstitial space or the manifold. If there
are low points in the connecting lines and lines are laid out of doors as well, install
condensate traps at all low points.
(2) Lay suction and measuring lines at a downward angle to the manifold. If this is not
possible, place condensate traps at all low points.
(3) Connect a liquid stop valve to each connecting line to the interstitial space, against the
valve direction.
These prevent leaking liquids from entering the interstitial spaces of the other pipes.
(4) If stop cocks are installed in the connecting lines then they must be sealable in open
position.
4.5. Installation of Electric Connector Lines (Leak detectors –Indicating Device)
(1) Requirements for the Line:
- Shield when locally required
- Colour of the jacket: Gray (also other colours, but no blue)
- Outside diameter: 13 to 18 mm
- Number of leads: 5 (4 + PE) (Leads must be distinguishable)
- Cross section (VLX ../A-Ex) 1.5 mm2up to 200 m cable length, 2.5 mm2up to 500 m
- Cross section (VLX ../A-MV-Ex) 1.5 mm2up to 100 m cable length, maximum line
capacity: 120 nF/km
(2) If the cable is laid in a tray, it must only be laid together with cables for measurement and
control, not together with power cables.
(3) Fixed wiring, no plug or switch connections.
(4) Only a central indicating device (VLX ../ZME):
Every channel that is equipped with a leak detector in the central
indicating unit must be activated with the associated coding link.
A channel that is not occupied and is activated with the coding link will
show an alarm.
If the channel is occupied, but not activated via a coding bridge, the
operating lamp will not be illuminated and an alarm will not be displayed.
The pump running display runs independent of activation.
Non explosion-proof leak detectors can also be connected to the central indicating device
as they have a voltage-free contact that sets off an alarm.
4.6. Electrical Connection
(1) Power supply: 230 V –50 Hz.
(2) Observe GROUNDING.
(3) Fixed wiring, i.e., no plug or switch connections.
(4) Terminal layout:
2 Outer conductor (phase)
3 Neutral conductor
4/5 Outer signal (230 V in case of alarm, can be turned off by activating the switch
“audible alarm”.)

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21/24 Voltage-free contacts (opened in case of alarm or loss of power)
for VLX../A/ME und VLX ../A/ME-MV
21/22/24 voltage-free contacts (two-way) for VLX ../A/ZME
51 Connection between leak detector and indicating unit, A1 (ME, ZME, ME-MV)
52 Connection between leak detector and indicating unit, A2 (ME, ZME) resp.
N (ME-MV)
53 Connection betw. leak detector and indicating unit, N(ME, ZME) resp. L1(ME-MV)
54 Connection between leak detector and indicating unit, L1 (ME, ZME) resp.
L2 (ME-MV)
(5) Voltage may be only applied when
–all electric and pneumatic lines are connected properly.
–the housing lid for the Ex terminal box in the leak detector is closed.
4.6.1 Grounding and Equipotential Bonding
(1) The housing of the leak detector must be connected to the equipotential bonding of the
overall system by means of the ground stud provided for that purpose.
(2) The fittings in the connecting lines must likewise be integrated into the equipotential
bonding, especially when plastic pipes (connecting lines to tanks) have been used.
(3) Before replacing a leak detector (working unit), disconnecting lines or similar work, it must
be ensured that the equipotential bonding remains intact (if necessary, pull electrically
conducting bridges).
4.7. Additional Notes for Underground Tanks/Pipes
If a tank/pipe is installed in a KKS system (cathode corrosion protection) that requires voltage
isolation, then electrical isolators need to be installed in the pneumatic lines. These isolators
must be provided with overload protection (spark plug gaps) and the isolators need to be
protected against accidental bridging.
4.8. Installation Examples
Installation examples are given in the Appendix.
Observe the following at all times:
The 82 pipe unions (connection for installation pump) are listed in the installation examples only
as examples. These pipe unions can be installed anywhere. These pipe unions are not needed,
when, for example, the test valve is used to connect the vacuum generator.
1. Installation example L/M –02:
–The laying system can also be combined with L –01
2. Installation example L/M –03:
TOP: If there is a liquid leak in the (suction line side) first pipe, the interstitial space for the
second (and following) pipes can also become filled with liquid.
The length of the measuring line must not exceed 3.5 m, if it does, use of a pressure
compensation vessel as per section 4.4.
CENTER and BOTTOM:
The liquid stop valve, installed against the direction of flow, (27*) prevents that the

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other interstitial spaces become filled with liquid in case of a leak in a pipe.
The volumes of the connected pipes must meet the following conditions:
3 VÜR 1 > VÜR 1 + VÜR 2 + VÜR 3 + VÜR 4 and
3 VÜR 2 > VÜR 2 + VÜR 3 + VÜR 4 usw.
VÜR (Zahl) is the volume of the respective interstitial space. No. 1 is the interstitial
space where the suction lines are connected (comp. L/M-03, center and bottom)
5. Start Up
(1) Connect the pneumatic lines.
(2) Complete the electrical wiring, but do not yet connect to the power supply.
(3) Close the lids on the explosive protected terminal box and the housing.
(4) Apply voltage supply.
(5) Determine illumination of the operating and alarm lights, as well as the audible alarm and
turn the “Audible Alarm” switch to OFF.
(6) Set three-way valve 21 to position “III” and connect the vacuum gauge. (Compare P-096 000)
b) V4a Version: Connect the stop cock on the measuring side in position 2 and connect the
vacuum gauge. (compare P-098 000)
Connect only suitable equipment to the 3-way cocks in suction and measuring line
(categorie 1 (inside) for interstitial spaces of zone 0, categorie 2 (inside) for interstitial
space of zone 1)
(7) Apply a vacuum to the system. (when necessary, use explosion-proof installation pump
(Caution: Be aware of temperature code and gas group!)
Connect installation pump to pipe union 82, switch it on and open the appropriate stop
cock. The interstitial space will then be evacuated. Monitor the vacuum build up on the
measuring instrument.
NOTE: If no pressure build up is achieved with the installation pump connected, the leak
must be located and corrected (check the performance of the installation pump as well, if
necessary).
(8) After the operating vacuum of the leak detector has been achieved (pump in the leak
detector switches off
12
), close the opened stop cock, switch off the pump and remove it.
(9) a) Put the three-way valve 21 in position I, remove the vacuum gauge.
b) V4A Version: Connect the stop cock on the measuring side in position 1 and connect the
pressure measuring instrument.
(10) Perform the function test per section 6.4.
6. Operating Instructions
6.1. General Notes
(1) If the leak detection system is installed properly and tightly, it can be assumed that the leak
detector works within the control range.
12
In the magnetic valve version the pump stands still in the event of an alarm. When the switch value for alarm OFF
is exceeded, the pump is switched on and stops again when it reaches the pump OFF switch value.

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(2) Frequent switching on or continuous running of the pump indicates leaks, which should be
corrected within a reasonable time.
(3) If the alarm goes off, this always indicates a more significant leak or a defect. Determine
the cause and correct it shortly.
(4) The operator must check the function of the operating lights at regular intervals.
(5) For any repair work, disconnect the power to the leak detector and check for explosive
atmosphere, if necessary.
(6) Explosion protection requirements must be satisfied (where necessary), such as laws on
the basis of the European Directive 1999/92/EG and/or other applicable codes.
(7) CAUTION: For single-walled tanks, equipped with a flexible leak detector lining, the
interstitial space can never be without pressure (collapse of the leak detection lining).
(8) A loss of power is indicated by the “Operating” signal light switching off. A loss of power to
the relay contacts (if used for alarm transmission) triggers the alarm.
After the power loss, the green signal light illuminates again and the voltage-free contacts
no longer generate an alarm (unless the power loss has caused the pressure to drop below
the alarm pressure
13
).
(9) To clean the leak detector, use a moist cloth.
6.2. Intended Use
Double-walled tanks and pipes/hoses
tank-/pipe-/hose-side flame arresters
leak detector side flame arresters may be used under the mentioned conditions
Grounding as per EN 1127
The leak detection system must be tight according to the table in the documentation
Leak detector installed outdoors, i.e. outside or inside the potentially explosive area (inside
the building possible if the listed requirements are met)
Explosive vapor-air mixtures: IIA to II B3, T1 to T3(T4)
Conduits inside and outside of the manhole or inspection chamber must be sealed gas-tight
The power supply cannot be disconnected
6.3. Maintenance
(1) Maintenance work and function tests may be performed by trained personnel only
14
.
(2) Once a year
15
to ensure functional and operational safety.
(3) Test scope per section 6.4.
(4) Compliance with the conditions per sections 4 to 6.3 must also be tested.
(5) Disconnect the power to the leak detector before opening the housing.
(6) The conditions in sec. 4.5.1 must be observed and complied with all times.
13
In the MV version, this also means that the Start Up switch must be switched again to restart.
14
For Germany: specialist or under the supervision of a specialist.
For Europe: Authorization from the manufacturer.
15
For Germany: regulations of the respective Länder must also be observed (e.g., AwSV)

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(7) As part of the annual function test, check the motor of the pump for running noises
(damaged bearings).
(8) If the pump has to be changed or when working on the pumps exhaust line a pressure test
of the suction- and measuring line with 10 bar has to be carried out for the parts inside the
housing.
(9) For exchange or repair-work take care that the venting-measures are given (Distance
between housing and flange plate >2.5 mm).
(10) Additional for the the version with solenoid valve (VLX ../A-MV-Ex):
If the solenoid has to be exchanged, take really care, that the system is pressureless
and free of liquid.
Never pull off the magnetizing coil from the body, while the leak detector is powered.
6.4. Function Testing
The functional and operational safety tests must be performed
after each startup
according to section 6.3,
each time a malfunction has been corrected.
The explosion-protection measures must be considered in all function testing.
Connect only suitable equipment to the 3-way cocks in suction and measuring line
(categorie 1 (inside) for interstitial spaces of zone 0, categorie 2 (inside) for inter-
stitial space of zone 1)
6.4.1 Test Scope
(1) If necessary, coordinate the work to be performed with those responsible for operation.
(2) Observe the safety instructions for working with the stored product.
(3) Check and, if necessary, empty the condensate traps (6.4.2).
(4) Check the free passage of air in the interstitial space (section 6.4.3).
(5) Test the switch values with the interstitial space (section 6.4.4)
alternatively: Test the switch values with the testing device (section 6.4.5).
(6) Test the vacuum pump delivery (section 6.4.6).
(7) Test the leak detection system for tightness (section 6.4.7).
(8) Create the operating conditions (section 6.4.8).
(9) A qualified person must complete a test report, confirming functional and operational
safety.
6.4.2 Checking and if necessary emptying of the condensate trap
(1) Close any shut-off valves on the interstitial space side.
(2) a) Set three-way valves 20 and 21 to position IV to ventilate the connection lines. (P-096 000)
b) V4A Version: set measuring and suction line side stop cock to position 2. (P-098 000)
(3) Open and empty the condensate traps.
CAUTION: The condensate traps may contain the stored/conveyed product. Take
appropriate protective measures.

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(4) Close the condensate traps.
(5) a) Set three-way valves 20 and 21 to position I. (P-096 000)
b) V4A Version: set measuring and suction line side stop cock to position 1. (P-098 000)
c) MV Version: Additionally activate „start up“ switch if the leak detector alarm in active.
(6) Open the stop cocks on the interstitial space side.
6.4.3 Checking the Free Passage of Air in the Interstitial Space
(1) a) Connect measuring instrument to three-way valve 21, then set to position III. (P-096 000)
b) V4A Version: Connect the measuring instrument to the stop cock on the measuring line
side, and set to position 2. (P-098 000)
(2) For tanks and pipes per installation example L/M -3:
a) Set three-way valve 20 to position IV. (P-096 000) b) V4A Version: open suction line side
stop cock (P-098 000)
For pipes as per installation example L/M-1 and L/M-2: Open the test valve at the end
opposite the leak detector; in case of multiple pipe interstitial spaces, the test valves must
be opened sequentially at the end opposite the leak detector.
(3) Check if the measuring instrument registers a vacuum drop. If no pressure drop occurs,
locate and correct the cause.
(4) Close three-way cock 20 in position I, or suction line side stop cock (V4A Version) of test
valve(s) respectively.
(5) a) Set three-way valve 21 to position I. (P-096 000)
b) V4A Version: Close measuring line side stop cock. (P-098 000)
(6) Remove the measuring instrument.
6.4.4 Testing the Switch Values with the Interstitial Space
(1) Connect the measuring instrument to three-way valve 21, position III. (P-096 000)
b) V4A Version: Connect the measuring instrument to the stop cock on the measuring line
side, and set to position 2. (P-098 000)
(2) For tanks and pipes per installation example L/M -3:
a) Ventilate with three-way valve 20 (position III). (P-096 000)b) V4A Version: Ventilate with
the suction line side stop cock (position 2) (P-098 000)
For pipes as per installation example L/M-1 and L/M-2: Open the test valve at the end of
the interstitial space opposite the leak detector. In case of multiple pipes, the leak detector-
side stop cocks of the interstitial spaces not included in the test can be closed.
(3) Check switch values “Pump ON” and “Alarm ON” (with visual and audible alarm, if
available). Record the values.
(4) Activate ”Audible Alarm” switch.
(5) Set three-way valve 20 to position I and close suction line side stop cock (V4A Version) or
test valve (in MV version, switch “Start Up” valve) and check switch values "Alarm OFF”
and "Pump OFF”. Record the values.
(6) The unit passes the test if the measured switch values fall within the specified tolerance.
(7) Open any stop cocks that were closed prior to the test.
(8) a) Set three-way valve 21 to position I. (P-096 000)
b) Set measuring line side stop cock to position 1. (P-098 000)
(9) Remove the vacuum gauge.

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6.4.5 Testing the Switch Values with the test equipment
(1) Connect the testing device to the two hose ends on each of the free pipe unions of three-
way valves 20 and 21. (P-096 000 and P-115 392-a)
b) V4A Version: Connect the testing device with both hose ends to each of the free pipe
unions of the suction and measuring line side stop cocks. (P-098 000 and P-115 392-b)
(2) Connect the measuring instrument to the tee of the testing device.
(3) Close the needle valve of the testing device.
(4) a) Set three-way valves 20 and 21 to position II. The operating vacuum is built up in the
test vessel. (P-096 000 and P-115 392-a)
b) V4A Version: Close both stop cocks on the interstitial space side. Set the suction and
measuring line side stop cocks to position 2. The operating vacuum builds up in the test
vessel. (P-096 000 and P-115 392-b)
b) MV Version: Turn switch “Start Up”, (Build-up of operating vacuum).
(5) Ventilate using the needle valve, check switch values “Pump ON” and “Alarm ON” (visual
and audible, if necessary). Record the values.
(6) if necessary, Activate ”Audible Alarm” switch.
(7) Slowly close the needle valve and check switch values “Alarm OFF” and “Pump OFF”.
(Turn “Start Up” MV version switch)
(8) The unit passes the test if the measured switch values fall within the specified tolerance.
(9) a) Set three-way valves 20 and 21 to position I. (P-096 000)
b) V4A Version: Set suction and measuring line stop cock to position 1 (P-098 000), open
interstitial space side stop cock.
(10) Remove the testing device.
6.4.6 Testing the Vacuum Pump Delivery
(1) Connect the measuring instrument to three-way valve 20 and set to position II. (P-096 000)
b) V4A Version: Close both stop cocks on the interstitial space side. Connect measuring
instrument to the stop cock on the suction line side, and set to position 2. (P-098 000)
(2) a) Set three-way valve 21 to position II to ventilate the vacuum switch. The alarm is
triggered and the pump runs. (P-096 000)
b) V4A Version: Set measuring line side stop cock to position 2 to ventilate the vacuum
switch. The alarm is triggered and the pump runs. (P-096 000)
c) MV Version: Turn switch “Start Up”, the pump runs.
(3) Read the delivery rate of the pump from the measuring instrument.
(4) The test has been passed when the pressure value reached > 150 mbar (type 34) and/or
> 550 mbar (type 330).
(5) a) Set three-way valves 20 and 21 to position I. (P-096 000)
b) V4A Version: Set suction and measuring line stop cock to position 1 (P-098 000), open
interstitial space side stop cock.
c) MV Version: Turn switch “Start Up” back.
(6) Remove the measuring instrument.
6.4.7 Leak Detection System Tightness Testing
(1) Check that all stop cocks between the leak detector and interstitial space are open.

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(2) Connect the measuring instrument to three-way valve 21, position III. (P-096 000)
b) V4A Version: Connect the measuring instrument to the stop cock on the measuring line
side, and set valve to position 2. (P-098 000)
(3) The vacuum pump must have reached the Pump OFF switch value for the tightness test.
Wait for a possible pressure compensation and then start the tightness test.
(4) The test is positive if the values of the following table are met. A higher pressure drop
means a higher load on the wear parts.
Interstitial space volume in liters
1 mbar pressure drop in
100
9 minutes
250
22 minutes
500
45 minutes
1000
1.50 hours
1500
2.25 hours
2000
3.00 hours
2500
3.75 hours
3000
4.50 hours
3500
5.25 hours
4000
6.0 ours
(5) a) Test valve in position I
b) V4A version: measuring line side stop cock in Position 1 (P-098 000)
(6) Remove the measuring instrument.
6.4.8 Creating the Operating Conditions
(1) Set the "Audible Alarm" switch to seal screw position and seal.
For central indicating device: if necessary, Press "Audible Alarm” button – the red LED may
not be illuminated.
(2) Seal the housing.
(3) Seal the stop cocks (between the leak detector and interstitial space) for each connected
interstitial space in the open position.
(4) Ensure again that the 3-way-cocks are the position I.
6.5. Alarms
(1) If an alarm goes off, one must assume that there is an explosive vapor-air mixture in the
interstitial space. Take appropriate protective measures.
(2) An alarm is indicated by the “Alarm” signal lighting up and the sounding of the audible
signal, if available.
(3) Close any stop cocks in the connecting line between the interstitial space and leak detector.
(4) Shut off the audible signal by activating the “Audible alarm” switch.
(5) Inform the installation company.
(6) The installation company must detect the cause and correct it. CAUTION: Depending on the
tank, there could be liquid under pressure in the connection lines.

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CAUTION: Do not allow the interstitial space in the tanks with flexible leak detector jackets
to become pressureless (collapse of the insert).
(7) Repairs to the leak detector (e.g. replacement of components) may only be made outside
the ex-area or suitable proction measures shall be established.
(8) Perform the function test per section 6.4, observing the conditions from sections 4 to 6.3.
7. Removal
For removal, the following points must be observed in particular:
Make sure the unit is free of gas before and during removal (see also section 4 above).
Seal any openings gas-tight through which the explosion atmosphere can carry over.
Avoid using spark-producing tools (saws, parting grinders, etc.) for removal whenever
possible. If this is unavoidable, be certain to observe EN 1127.
Avoid the buildup of electrostatic charges (e.g., through friction).
Properly dispose of contaminated components (possibly through outgassing).
8. Marking
Type
Electrical data
Manufacturer or manufacturer symbol
Date of manufacture (month/year)
Serial number
Symbol specified by law
Explosion data
9. Index Used
01 ”Alarm” signal light, red
02 Stop cock
03 Exhaust line
09 ”Operating” signal light, white
11 Vacuum switch
18 Explosion protection device
20 Three-way valve in suction line
21 Three-way valve in measuring line
22 Tank venting
24.1 Fine-wire fuse 1 A MT (H)
24.2 Fine-wire fuse 2.5 A MT (H)
24.3 Fine-wire fuse 0.1 A T (H)
27 Liquid stop valve
27* Liquid stop valve, inst. against direction of flow
30 Housing
33 Condensate trap
34 Terminal box
36 "Start-up" switch
41 Alarm switch in 11
42 Pump switch in 11
43 Measuring line

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44 Solenoid Valve
45 Signal light “Feed, yellow (= pump on)
48 ”Network” signal light, green
52 Vacuum gauge
57 Test valve
59 Relay
60 Vacuum pump
68 Suction line
69 Buzzer
71 ”Audible Alarm” switch
73 Interstitial space
74 Connecting line
82 Installation pump connection
84 1 liter test vessel
85 Test pipe unions (vacuum gauge)
86 Leak detecting device
87 Leak detector
88 Double-walled pipe
95 Pressure-compensating vessel
96 Node point
98 Sealing plug
101 Suction line leading to the low point

II
IIII
IIIIII
IVIV
21
21
21
21
20
20
20
20
15-01-2002 /01-2004 P - 096 000