SGB VLR Series Documentation

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

- 2 - 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 +49 0271 48964-0, 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

- 3 - 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

- 4 - 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

- 5 - 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  

- 6 - 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

- 7 - 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: o Compiling a risk assessment and implementing its results in a di- rective o Performing regular checks as to whether the directive is in compli- ance with the current standards o The directive includes information on how to react to an alarm that might arise o Arranging 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

- 8 - 2.4 Personal Protective Equipment Personal protective equipment must be worn during work. o Wear the necessary protective equipment for the work in question o Note 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

- 9 - 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

- 10 - 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

- 11 - 3.4 Field of Application 3.4.1 Pipelines/tubes In factory or on-site construction o Suction 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 o Pressure lines with feed pressures of up to 5 bar: Version VLR 330 to VLR 570 o Pressure lines with feed pressures of up to 25 bar: Version VLR 330 to VLR 570, each with solenoid valve o Pressure 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 o In 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). o For 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

- 12 - 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: o The materials used must be resistant to the liquids being moni- tored. o Liquids 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). o If 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

- 13 - 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

- 14 - 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

- 15 - 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 

- 16 - 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. 2 The “Sound off” key does not have a function, which means the audible signal cannot be turned off. Indicator light Operating condition Alarm vacuum below “ Alarm ON” 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

- 17 - 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)

- 18 - 5. Mounting the System 5.1 Basic Instructions o Prior to commencing work, the documentation must be read and understood. In case of ambiguities, please ask the manufacturer. o Observe the approvals of the manufacturer for the pipeline and the interstitial space. o The safety instructions in this documentation must be adhered to. o Only qualified service companies may be used for assembly and commissioning3. o Lead-throughs for pneumatic and electric connection lines must be sealed gas-tight. o Comply with relevant regulations regarding electric installation and regulations for prevention of accidents. o Pneumatic connections, connection lines, and fittings must with- stand the excess pressure that may occur over the entire tempera- ture range. o Before entering inspection chambers, the oxygen content must be tested and the inspection chamber flushed if necessary. o When using metallic connection lines, proper equipotential bond- ing must be ensured; alternatively, electrical isolators must be used. 5.2 Assembly of the Leak Detector o Wall mounting using the supplied mounting material. o Outside of the potentially explosive area (zone 1 or 2), also applies to the connection lines and interstitial space. o Plastic housing: In a dry room Stainless steel housing: Outdoors, without additional protective box o To 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). o Ventilation systems must be kept clear. o Do not mount in access or inspection chambers. 3 For Germany: Specialist service companies as per German water legislation that have documented qualifi- cations to install leak detection systems. Mounting

- 19 - 5.3 Pneumatic Connection Lines 5.3.1 Requirements o At least 6 mm inside clearance o Resistant to the stored or conveyed product o Pressure and vacuum-resistant across the entire temperature range o The full cross section must be maintained (not bent) o Color coding: Measuring line: RED; Suction line: WHITE or CLEAR; Exhaust: GREEN. o 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. o Condensate traps must be installed at all low points of the connec- tion lines. o Assemble liquid stop valve in the suction line (generally included in the assembly kit). 5.3.2 Exhaust o The exhaust line can lead outside to a safe4 area: Fit a condensate trap and a liquid stop valve in the exhaust line. o Caution: 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 o Lay 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. o Lay suction and measuring lines at a downward angle to the mani- fold. If this is not possible, place condensate traps at all low points. o Connect 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. o If shut-off cocks are installed in the connection lines, then they should be sealable in the open position. 4 Among other things, not accessible to public transport/persons Mounting

- 20 - o For 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 o OR (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: o Unscrew protective cap o Re-tighten lock nut o Unscrew valve insert and stick next to the connection with ad- hesive tape. (As evidence of disassembly) o Screw connection to the interstitial space or test valve and fas- ten finger-tight o If necessary, further tighten with suitable pliers 5 If this volume is multiplied, Lmax is multiplied in the same way. Mounting

- 21 - 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 manhole chamber is entered (3) Complete the relevant connection (according to the illustrations in the following images) 5.4.2.1 Flanged screw connection (for flanged pipes) (1) Lubricate O-rings (2) Insert spacer ring loosely into the screw socket (3) Slide union nut and pressure ring over the pipe (4) Hand-tighten union nut (5) Tighten union nut until need for increased force is clearly notice- able (6) Final assembly: Tighten by another ¼ turn 5.4.2.2 Clamping ring screw connection for metal and plastic pipes (1) Insert support sleeve (only plastic pipes) into end of the pipe (2) Insert pipe (with support sleeve) all the way to the stop (3) Screw fitting up until the resistance rises sharply (~1¾ turns!) (4) Loosen nut (5) Tighten the nut by hand up to a noticeable stop (6) Finish assembling the screw connection by tightening a ¼ turn 5.4.2.3 Quick screw connections for PA pipes (1) Cut PA pipe to length at a right angle (2) Unfasten union nut and slide over the end of the pipe (3) Slide pipe onto nipple up to the beginning of the thread (4) Hand-tighten union nut (5) Wrench-tighten union nut until need for increased force is notice- able (approx. 1 to 2 turns) 5.5 Electrical Cables The electrical connection lines should be resistant to the existing or expected vapors and liquids. Cross section of 1.0 mm2 to 2.5 mm2 Outer cable diameter of 5.5 to 13 mm. If other cable diameters are used, the screw connections need to be replaced to provide proper protection. Mounting

- 22 - 5.6 Electrical Wiring Diagram (1) Fixed wiring, i.e., no plug or switch connections. (2) Observe the requirements for electric installations, if necessary, also those of the electric companies. (3) Terminal layout: (see also SL 854 851) 1/2 Power connection (100–240 V AC) 3/4 Occupied (vacuum pump) 5/6 External signal 24 V DC, can be disconnected 7/8 Solenoid valve 70/71 Probe contacts; the potential-free contacts of a leak de- tection probe can be connected here 11/12 Potential-free contacts (opened in case of alarm or loss of power) 12/13 As above, but contacts closed (17/18) Potential-free contacts, in parallel with pump running (closed when pump is inactive and in case of loss of power) (18/19) As above, but contacts open 40/41 24 V DC as permanent power supply to power other as- semblies or, for a device with a supply voltage of 24 V DC, the power supply is connected here (4) Do not apply voltage until all electrical and pneumatic cables are connected and the housing cover is closed. Mounting

- 23 - 5.6.1 Connecting the wires (1) Press down the orange point with a screwdriver. This opens the tension spring of the terminal (2) Insert the cable into the open terminal. (3) Hold the cable and remove the screwdriver. (4) Check the cable for a tight fit and connect more cables to the terminals using the same process. 5.6.2 Data bus module (DBM) The data bus module is used to provide the status and operating data for the inquiry via the data bus of the higher-level display equipment (DDU). The aforementioned module is installed in the leak detector housing by the manufacturer when the order is placed. The DBM is connected to the display device (indicating unit) DDU by the customer. For details regarding the connection, see the documentation for the DDU. Mounting

- 24 - 5.6.3 Block diagram (SL 854 851) 44 Solenoid valve 60 Pump (24 V DC) 76 Main board 90 Temperature switch 91 Heating 97 Leak detection probe 102 Pressure sensor 103 Display 128 Switching power supply 139 Keypad 146 Solenoid valve monitoring board (MVÜ board) 169 Data bus module (DBM) Mounting 5 4 3 2 1 6 PE N L +24 40 8 71 70 40 41 7 3 41 +24 gnd 5 22 21 13 6 12 4 +5V +5V 1 100 - 240 V AC 50 Hz L 18 10 9 19 N PE 24 V DC 2 SDR 17 11 - + 102 146 128 60 91 90 76 44 97 P 24 VDC 139 169 103

- 25 - 5.7 Installation Examples 5.7.1 Double-walled pipe, connected in parallel, with solenoid valve in the suction line. To be used for feed pressures < 5 bar in the inner pipe. Version VLR .. 02 Shut-off valve 20 Three-way valve, suction line 21 Three-way valve, measuring line 27 Liquid stop valve 27* Liquid stop valve, connected against the flow direction 43 Measuring line 57 Test valve 68 Suction line 74 Connection line 88 Double-walled pipe 95 Pressure compensation vessel 96 Node point 88 68 27 27* 96 74 02 95 43 57 bar bar bar H max H max H max 20 21 H max Mounting

- 26 - 5.7.2 Double-walled pipe, connected in parallel, with solenoid valve in the connection line. To be used for feed pressures 5 bar > p < 25 bar in the inner pipe. Version VLR .. MV 02 Shut-off valve 44 Solenoid valve 20 Three-way valve, suction line 57 Test valve 21 Three-way valve, measuring line 68 Suction line 27 Liquid stop valve 74 Connection line 27* Liquid stop valve, connected 88 Double-walled pipe against the flow direction 95 Pressure compensation vessel 43 Measuring line 96 Node point 88 68 27 27* 96 74 02 95 43 57 bar bar bar H max H max H max 20 21 44 H max Mounting

- 27 - 5.7.3 Double-walled pipe with solenoid valve in the connection line and additional pressure switch. To be used for feed pressures 25 bar > p < 90 bar in the inner pipe. 02 Shut-off valve 20 Three-way valve, suction line 21 Three-way valve, measuring line 27 Liquid stop valve 43 Measuring line 44 Solenoid valve 57 Test valve 68 Suction line 74 Connection line 88 Double-walled pipe 95 Pressure compensation vessel 96 Node point 148 Additional pressure switch ZD- 68 27 96 95 43 20 21 44 88 148 74 02 57 H max Mounting

- 28 - 5.7.4 Double-walled pipe, connected in parallel (node point in the manifold) 02 Shut-off valve 20 Three-way valve, suction line 21 Three-way valve, measuring line 27 Liquid stop valve 27* Liquid stop valve, connected against the flow direction 43 Measuring line 57 Test valve 68 Suction line 74 Connection line 88 Double-walled pipe 95 Pressure compensation vessel 96 Node point 88 68 27 27* 96 74 02 95 43 57 < H max < H max < H max bar bar bar 20 21 H max Mounting

- 29 - 5.7.5 Double-walled pipe, connected in series 02 Shut-off valve 20 Three-way valve, suction line 21 Three-way valve, measuring line 27 Liquid stop valve 43 Measuring line 68 Suction line 82 Nozzle for assembly pump 88 Double-walled pipe 68 27 43 20 21 88 27 82 02 02 0 < .... < H max V V ÜR 1 ÜR 2 Mounting

- 30 - 5.7.6 Double-walled pipe, individual pipe with low vacuum 20 Three-way valve, suction line 21 Three-way valve, measuring line 27 Liquid stop valve 43 Measuring line 57 Test valve 68 Suction line 74 Connection line 88 Double-walled pipe 95 Pressure compensation vessel 96 Node point Here: must (geodetically) be under 157! 157 Lowest point of the interstitial space 88 68 27 96 74 27 157 95 43 57 20 21 VLR 34 < 0,3 m Mounting

- 31 - 6. Commissioning (1) Only perform commissioning once the steps in Section 5 “Mount- ing” have been completed. (2) If a leak detector is operated on an interstitial space that is al- ready in operation, special protective measures must be taken (for example, checking that there is no liquid in the interstitial space). Additional measures may be necessary depending on the local conditions and must be assessed by qualified person- nel. 6.1 Tightness Test Prior to commissioning, ensure the leak-tightness of the interstitial space. The vacuum build-up (depending on the pressure level of the leak de- tector) should be executed using an external vacuum pump. The starting vacuum for the tightness test should not be below the operating pressure of the leak detector (value for Pump OFF). The test is generally considered passed if the vacuum does not drop by more than 1 mbar within a test period (in minutes) calculated from the interstitial space volume divided by 10. E.g.: The test period for an interstitial space volume of 800 liters is: 800/10 = 80 minutes. Within this test period, the vacuum must not fall below 1 mbar. 6.2 Commissioning the Leak Detector (1) Tightness of the interstitial space prior to commissioning is as- sumed. (2) Connect voltage supply. (3) Ascertain lighting of “Operation” and “Alarm” signal lamps and sounding of the audible alarm. If necessary, turn off audible alarm signal. The vacuum pump starts immediately and builds up the vacuum in the monitored system (if the interstitial space has not already been evacuated). Note: If the VLR .. MV is used, it must be ensured that the probe contacts (9/10) are bridged and a solenoid valve (24 V DC) is connected to terminals 7 and 8. (4) Attach the measuring gauge to the connection on three-way valve 21 in order to turn the valve 180°. (5) The vacuum build-up can be monitored via the connected meas- uring gauge. (6) If the vacuum build-up is too slow, an assembly pump can be at- tached to the connection on three-way valve 20. Commissioning 21 20 21 20 

- 32 - Turn the valve 180° and switch on the assembly pump. (7) After the operating vacuum of the leak detector has been reached (pump in leak detector shuts off), turn three-way valve 20 180°, switch off the assembly pump, and remove it. (8) Turn three-way valve 21 180° and remove the pressure measur- ing gauge. (9) Perform a functional check according to Section 7.3. 21 20 Commissioning

- 33 - 7. Functional Check and Maintenance 7.1 General (1) If the leak detection system has been properly installed and is free of leaks, trouble-free operation can be assumed. (2) Frequent switching on or continuous running of the pump indi- cates leaks, which should be corrected within a reasonable peri- od of time. (3) In the event of an alarm, determine the cause and correct it quickly. (4) The operator must check the function of the operating lights at regular intervals. (5) The leak detector must be disconnected from the power when performing any repairs. (6) A loss of power is indicated by the “Operation” indicator light go- ing off. Alarm signals are triggered via the potential-free relay contacts if contacts 11 and 12 were used. After the power loss, the leak detector automatically goes into operation again and the potential-free contacts no longer gener- ate an alarm (unless the power loss has caused the pressure to drop below the alarm pressure). (7) CAUTION: For single-walled tanks equipped with a flexible leak protection lining, the interstitial space can never be without pres- sure (risk of collapse of the leak protection lining)! 7.2 Maintenance o Maintenance work and functional checks must be performed by trained personnel only6. o Once a year to ensure functional and operational safety. o Test scope according to Section 7.3. o Compliance with the conditions in Sections 5 and 6 must also be tested. o As part of the annual functional check, check the motor of the pump for running noises (damaged bearings). o If the pump or its exhaust pipe is exchanged or detached, then a tightness test should be carried out for the installed pump with a pressure of 10 bar after the exchange in order to ensure the im- permeability of the exhaust in the housing. 6 For Germany: Technical service according to water legislation with expertise in leak detection systems For Europe: Authorization by the manufacturer Functional Check and Maintenance 

- 34 - 7.3 Functional Check The functional and operational safety check must be performed: o After each commissioning process o According to the time intervals given in Section 7.27 o Each time a malfunction has been corrected Two persons may be required to perform a functional check, depend- ing on the length of pipeline and how it is laid. The following aspects must be observed or carried out: o Coordinate the work to be performed with those responsible for operation o Observe the safety instructions for working with the product to be conveyed o Check the condensate traps and empty if necessary (7.3.1) o Check the free passage of air in the interstitial space (7.3.2) o Test the switching values with the interstitial space (7.3.3) Test the switching values with the testing device (7.3.4) o Test the pump delivery pressure (7.3.5) o Perform a system tightness test (7.3.6) o Check the excess pressure alarm (only for version with solenoid valve) (7.3.7) o Check the additional pressure switch in conjunction with VLR .. (version with solenoid valve) (7.3.8) o Check the probe (if used) (7.3.9) o Create the operating condition (7.3.10) o A test report must be completed, confirming functional and opera- tional safety. Test reports are available for download from the SGB website 7.3.1 Checking free passage of air in the interstitial space Checking the free passage of air ensures that an interstitial space is connected to the leak detector and that it has sufficient passage to cause an air leak to trigger an alarm. (1) Attach the measuring gauge to the connection on three-way valve 21 and turn the valve 180°. (2) Open the test valve at the end opposite the leak detector; if there are multiple pipe interstitial spaces, the test valves must be opened sequentially at the end opposite the leak detector. (3) Check if the measuring gauge registers a vacuum drop. If no pressure drop occurs, locate and correct the cause. (4) Return the three-way valves to the operating position and remove the measuring gauge. 7 For Germany: In addition, national laws apply (e.g., AwSV) Functional Check and Maintenance 21 20 21 20 20 21

- 35 - 7.3.2 Testing the switching values with the interstitial space (1) Attach the measuring gauge to the connection on three-way valve 21 and turn the valve 180°. (2) Open the test valve at the end opposite the leak detector; if there are multiple pipe interstitial spaces, the leak detector-side shut- off cocks of the interstitial spaces not included in the test can be closed. (3) Check switching values “Pump ON” and “Alarm ON” (with visual and audible alarm, if available). Record the values. (4) Activate the “Sound off” key, if necessary. (5) Return three-way valve 20 to its original position or close the test valve and check the switching values “Alarm OFF” and “Pump OFF”. Record the values. (6) The unit passes the test if the measured switching values fall within the specified tolerance. (7) Open any shut-off cocks that were closed prior to the test. (8) Return the three-way valves to the operating position and remove the measuring gauge. 7.3.3 Testing the switching values with the testing device (see Section “Accessories”) (1) Connect the testing device to the two tube ends on each of the free connections of three-way valves 20 and 21. (2) Connect the measuring gauge to the T-piece of the testing de- vice. (3) Close the needle valve of the testing device. (4) Turn three-way valve 20 90° (counterclockwise) and three-way valve 21 90° (clockwise) so that the interstitial space is discon- nected. The interstitial space volume is now simulated by the test tank. (5) The operational vacuum is now established in the test tank. (6) Ventilate slowly using the needle valve; check switching values “Pump ON” and “Alarm ON” (visual and audible, if necessary). Record the values. (7) Press the “Audible alarm” button if necessary. (8) Slowly close the needle valve and check switching values “Alarm OFF” and “Pump OFF”. (9) The unit passes the test if the measured switching values fall within the specified tolerance. (10) Turn back three-way valves 20 and 21 and remove the testing device. 21 20 21 20 21 20 21 20 21 20 21 20 Functional Check and Maintenance

- 36 - 7.3.4 Testing the pump delivery pressure The test of the delivery pressure of the pump is carried out in order to determine if the vacuum source is capable of establishing the operat- ing vacuum in the interstitial space. (1) Attach the measuring gauge to the connection on three-way valve 20 and turn the valve 90° (counterclockwise). (2) The pump is usually not running at this moment, i.e., the pres- sure sensor must be vented to start the pump. (3) Turn three-way valve 21 90° (clockwise). The pressure sensor is vented, the pump starts (and the alarm is triggered, acknowledge if necessary). (4) This unit passes the test if the suction height of the vacuum pump is at least 40 mbar higher than the switching value “Pump OFF” (i.e., the operational vacuum). (5) Once the test is complete, return the valves to their original posi- tions and remove the measuring gauge. 7.3.5 System tightness test (1) The system tightness requirement is defined in Section 6.1. Determine the test period for each interstitial space connected (and/or the entire monitored system) (calculate or use test re- ports prepared by SGB GmbH). (2) Attach the measuring gauge to the connection on three-way valve 21 and turn the valve 180°. (3) Read off and record the starting vacuum and time. Wait for the test period to elapse and determine the vacuum drop. (4) The test is considered passed if the vacuum does not drop by more than 1 mbar during the test period. Of course, a multiple of the test period can also be measured; in this case, the permissible vacuum drop is also a multiple. (5) Once the test is complete, return the valves to their original posi- tions and remove the measuring gauge. 7.3.6 Checking the excess pressure alarm (only for version with solenoid valve) (1) Attach the excess pressure testing device to the connection on three-way valve 21 and turn the valve 180°. (2) Then turn three-way valve 21 90°. (3) Apply pressure using the excess pressure testing device. First the pump is switched on, then the alarm is triggered (red LED Functional Check and Maintenance 21 20 21 20 21 20 21 20 21 20 21 20 21 20

- 37 - on), and if the pressure continues to increase, the excess pres- sure alarm is triggered (yellow LED flashes). (4) With the excess pressure alarm, the pump is switched off and the solenoid valve closes. (5) Relieve excess pressure by detaching the excess pressure test- ing device. The excess pressure alarm stops and the pump runs; the solenoid valve opens. (6) Once the test is complete, return the valves to their original posi- tions and remove the measuring gauge. 7.3.7 Checking the additional pressure switch in conjunction with VLR .. MV (1) Connect the testing device as per Section 7.3.5 and complete steps (1) to (5). (2) Close the shut-off cock on the interstitial space side. (3) Connect an external pressure booster to connection 82 and open the relevant valve. (4) Pressure build-up until activation of the pressure switch (probe alarm is triggered and the solenoid valve switches). (5) Check the corresponding alarm(s). (6) Relieve pressure; probe alarm stops and the solenoid valve switches. (7) Close the shut-off cock at 82 and remove the pressure booster. (8) Open the shut-off cock on the interstitial space side, move three- way valves 20 and 21 into the operating position, and remove testing device 7.3.8 Checking the probe (only VLR .. with additional probe) (1) Bring the probe into the alarm state. Depending on the probe ver- sion, either by pressing a test button (“WHG probes”), by turning the housing (float), or by removing it and dipping it in test liquid. Note: If the probe is checked by removing it, the stop valves must be closed to maintain the vacuum in the interstitial space. Open again after the test! (2) Check the probe alarm as per Section 4.6.1 and the switching of the solenoid valve. (3) Establish the probe operating condition again; the probe alarm stops and the solenoid valve opens. 7.3.9 Achieving the operating condition (1) Test whether all pneumatic connections have been established correctly. 21 20 21 20 21 20  Functional Check and Maintenance

- 38 - (2) Check that the three-way valves are in the correct position. (3) Seal the housing. (4) Seal the shut-off cocks (between the leak detector and interstitial space) for each connected interstitial space in the open position. (5) Attach a sign with troubleshooting information. (6) Fill out a test report and hand over to the operating company. Functional Check and Maintenance

- 39 - 8. Malfunction (Alarm) 8.1 Alarm Description If an alarm goes off, one must assume that there are vapors stored in the interstitial space of the stored/conveyed product. Take appropri- ate protective measures. (1) An alarm (vacuum loss) is indicated by the red “Alarm” signal lamp lighting up and the sounding of the audible signal, if availa- ble. (2) Other alarms are indicated as follows: Probe alarm: Yellow LED that flashes when the audible signal is acknowledged. Pressure build-up alarm: Yellow LED flashes, red LED lights up. The red LED flashes when the audible alarm is acknowledged. (3) Close any shut-off cocks in the connection line between the in- terstitial space and leak detector. (4) Shut off the audible signal by activating the “Sound off” key, if available. (5) Inform the installation company. (6) The installation company must detect the cause and correct it. CAUTION: Depending on the tank/pipelines, there could be liq- uid under pressure in the connection lines. CAUTION: Do not depressurize the interstitial space in the tanks with flexible leak protection lining (risk of collapse of the in- sert)! (7) Perform a functional check as per 7.3. 8.2 Malfunction In the event of a malfunction, only the red signal lamp will light up in addition to the green signal lamp (yellow is off). Also, the audible sig- nal cannot be acknowledged. Solenoid valve malfunction (e.g., no power): Yellow LED lights up and the red LED flashes. 8.3 How to Behave The different alarms can be used for different automated reactions (e.g., switching off pumps). Inform the installation company. They need to find and rectify the er- ror. After repair, a functional check must be conducted. Malfunction (Alarm)

- 40 - 9. Spare Parts See: shop.sgb.de 10. Accessories You can find accessories on our website shop.sgb.de, for example: - Assembly kits - Electrical isolators - Manifolds with suction/measuring connections, expansion mani- folds (e.g., art. no. 195420, 195434) - Testing device/measuring equipment (e.g., art. no. 115392, 115360) - Pressure booster (e.g., art. no. 115376) Spare Parts/Accessories

- 41 - 11. Appendix 11.1 Dimension and drilling illustration 11.1.1 Plastic housing Depth = 110 Appendix 40 40 41 41 03 03 04 04 21 21 22 22 05 05 06 06 13 13 12 12 11 11 17 17 18 18 19 19 09 09 10 10 1L 1L 1L 1L 2N 2N 2N 2N + ---- - ++ ++ ON ON 1 2 33 44 5 6 7 8 9 10 10 209 ~35 ~100 115 115 265 170 Ø6 36 230 245

- 42 - 11.1.2 Stainless steel housing Depth = 80 mm Appendix 220 243 268 250 280 Ø8,5 310

- 43 - 11.2 Declaration of Conformity We, SGB GmbH Hofstrasse 10 57076 Siegen, Germany, hereby declare in sole responsibility that the leak detectors VLR .. and VLR .. MV are in conformity with the essential requirements of the EU directives listed below. If the device is modified in a way that has not been agreed with us, this declaration shall lose its validity. Number/short title Satisfied regulations 2014/30/EU EMC Directive EN 61000-6-3: 2011 EN 61000-6-2: 2006 EN 61000-3-2: 2015 EN 61000-3-3: 2014 2014/35/EU Low Voltage Directive EN 60335-1: 2012 EN 61010-1: 2010 EN 60730-1: 2011 Conformity is declared by ppa. Martin Hücking (Technical Director) As of: 02/2019 Appendix

- 44 - 11.3 Declaration of Performance (DoP) Number: 001 EU-BauPVO 2014 1. Unique identification code of the product type: Vacuum leak detector type VLR .. 2. Use: Vacuum leak detector of class I for monitoring double-walled pipes 3. Manufacturer: SGB GmbH, Hofstrasse 10, 57076 Siegen, Germany Phone: +49 271 48964-0; e-mail: [email protected] 4. Authorized representative: n/a 5. System for assessment and verification of constancy of performance: System 3 6. In case of a declaration of performance for a construction product which is covered by a har- monized standard: Harmonized standard: EN 13160-1-2:2003 Notified body: TÜV Nord Systems GmbH & Co.KG, CC Tankanla- gen, Große Bahnstraße 31, 22525 Hamburg, Germany Identification number of the notified testing laboratory: 0045 7. Declared performance: Essential characteristics Performance Harmo- nized standard Pressure switch points Passed EN 13160-2: 2003 Reliability 10,000 cycles Pressure test Passed Volume flow rate test in the alarm switch point Passed Function and tightness of the leak detection system Passed Temperature resistance -20°C to +60°C 8. Signed for and on behalf of the manufacturer by: Dipl.-Ing. M. Hücking, Technical Director Siegen, 20-09-2017 11.4 Declaration of Compliance of the Manufacturer (ÜHP) Compliance of the leak detector with the Specimen Administrative Provision of the Technical Building Regulations is hereby declared: Appendix

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- 48 - Text Text Legal notice SGB GmbH Hofstr. 10 57076 Siegen Germany T +49 271 48964-0 Photos and sketches are not binding for the scope of delivery. E [email protected] Subject to change without notice. W www.sgb.de © SGB GmbH, 05/2020 Text