SGB VLXE Series, VLXE 80, VLXE 230, VLXE 255, VLXE 330 Documentation

Documentation

Vacuum leak detector VLXE ..

Please read the instructions before commencing any work

Last updated: 10/2019

Item no.: 602 222

Contents

Table of Contents

1. General ....................................................................... 4

1.1 Information

1.2 Explanation of symbols

1.3 Limitation of liability

1.4 Copyright

1.5 Warranty

1.6 Customer Service

2. Safety .......................................................................... 6

2.1 Intended use

2.2 Responsibility of the operating company

2.3 Qualification

2.4 Personal protective equipment

2.5 Basic hazards

3. Technical Data ........................................................... 9

3.1 General data

3.2 Electrical data

3.3 Ex data

3.4 Switching values

3.5 Field of application

4. Design and function .................................................. 13

4.1 Design

4.2 Normal operation

4.3 Air leak

4.4 Liquid leak

4.5 Display and control elements

5. Installation of the system ......................................... 17

5.1 General notes

5.2 Installation of the leak detector

5.3 Pneumatic connection cables

5.4 Making pneumatic connections

5.5 Electrical lines

5.6 Electrical connection diagram

5.7 Installation examples

6. Commissioning ......................................................... 32

6.1 Tightness test

6.2 Commissioning of the leak detector

7. Functional check/maintenance ................................ 34

7.1 General

7.2 Maintenance

7.3 Functional check

8. Fault (Alarm) .............................................................. 39

8.1 Alarm description

8.2 Fault

8.3 Behavior

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9. Spare parts ................................................................. 40

10. Accessories ............................................................... 41

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Contents

11. Disassembly and disposal ........................................ 42

11.1 Disassembly

11.2 Disposal

12. Appendix ..................................................................... 43

12.1 Use on interstitial spaces that are
filled with leak detection liquid

12.2 Dimensions and drilling template

12.3 EU declaration of conformity

12.4 Declaration of performance

12.5 Manufacturer’s declaration of compliance

12.6 TÜV-Nord certification

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General

1. General

Information

This manual provides important information about how to handle the
VLXE leak detector. The precondition for safe working is compliance
with all of the specified safety notices and instructions for action.

In addition, all the applicable local accident prevention regulations
and general safety instructions must be complied with at the operat­ing site of the leak detector.

1.2 Explanation of symbols

Warnings in this manual are indicated by a symbol next to them.
The signal word expresses the level of risk.
DANGER:

An immediately hazardous situation that results in death or serious in­juries if not avoided.



1.3 Limitation of liability

WARNING:

A potentially hazardous situation that can result in death or serious in­juries if not avoided.

CAUTION:

A potentially hazardous situation that can result in minor or slight inju­ries if not avoided.

INFORMATION:
Highlights useful tips, recommendations and information.

All the data and information in this documentation have been com­piled taking account of applicable standards and regulations, the cur­rent state of technology and our many years of experience.

SGB will not accept liability for:

 Non-compliance with this manual
 Unintended use
 Deployment of unqualified personnel
 Unauthorized conversions
 Connection to systems not approved by SGB

1.4 Copyright



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The contents, texts, drawings, pictures, and any other representations
are protected by copyright and are subject to industrial property
rights. Any misuse is a criminal offence.

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1.5 Warranty

1.6 Customer Service

General

We provide 24 months of warranty on the VLXE .. leak detector from
the day of installation on-site in accordance with our General Terms
and Conditions of Sale and Delivery.

The warranty period is a maximum of 27 months from our date of
sale.

The prerequisite for any warranty is the presentation of the func­tion/test report about initial commissioning by trained personnel.
Specification of the serial number of the leak detector is required.

The warranty obligation is rendered null and void in the case of

- inadequate or incorrect installation,

- improper operation,

- changes/repairs made without the agreement of the manufacturer.

Our Customer Service department is available to provide you with in­formation.

You can find information about contacts on the World Wide Web at

www.sgb.de or on the rating plate of the leak detector.

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Safety

2. Safety

2.1 Intended Use

WARNING!

Danger from

misuse

 Leak detector fitted in the open air outside the explosion hazard

area (also possible in the building under the conditions listed)

 Conditions from Sec. 3.5 “Field of application” must be complied

with.

 Pressureless double-walled tanks and pressureless double-walled

pipes, if any explosive steam-air-mixtures and vapors that occur
comply with these conditions:

o Explosion group IIA to IIB3
o Temperature class T1 to T3
o Must be heavier than air

 Double-walled pipes with up to 5 bar conveyance pressure in the

inner pipe for liquids with a flashpoint > 60 °C (for Germany 55 °C)
and which end in the ex-area. Possible steam-air-mixtures and va­pors must comply with the following conditions:

o Explosion group IIA to IIB3
o Temperature class T1 to T3
o Must be heavier than air

 Only for monitoring spaces of double-wall tanks/pipelines with suf-

ficient resistance to underpressures

 Tightness of the monitoring spaces according to this documenta-

tion (Chap. 6.1.).

 Detonation flame arresters are to be used on the vessel/pipe.
 Ambient temperature -40°C … +60°C
 Penetrations in the manhole or control shafts must be closed off so

that they are gas-tight

 Power connection cannot be switched off
 Earthing/equipotential bonding in accordance with applicable regu-

lations

 Mains earth may be on the same potential as the equipotential

bonding of the tank/pipeline

Any claims resulting from misuse will not be accepted.

2.2 Responsibility of the operating company

The VLXE leak detector is used in the industrial sector. The operating
company must therefore comply with statutory occupational health
and safety requirements.

In addition to the safety information in this documentation, all the ap-

WARNING!

Hazard in the

case of incom-

plete documen-

tation

plicable safety, accident prevention and environmental protection
regulations must be complied with. In particular:

- Compilation of a hazard analysis and implementation of its results
in operating instructions

- Regular checking of whether the operating instructions comply with
the current state of regulations

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- The content of the operating instructions may also be the reaction
to a possible alarm

- Instigation of an annual functional check

2.3 Qualification

The personnel must be sufficiently qualified to recognize and avoid
possible dangers on their own.

Companies that put the leak detector into operation should have been

WARNING!

Danger to people

and environment in

case of insufficient

qualification

trained at SGB, by SGB or by the authorized representative.
National regulations must be complied with.

For Germany: Specialist company qualification for the installation,
commissioning and maintenance of leak detection systems.

2.4 Personal protective equipment (PPE)

Safety

Personal safety equipment must be worn during work.

- Wear the necessary protective equipment for the respective work

- Observe and comply with any signs concerning PPE

- For additional information see 12.2

Entry in the "Safety Book"

"Wear a warning vest"

Wear safety shoes

Wear a protective helmet

Wear gloves - where necessary

Wear protective goggles - where necessary

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Safety

2.41 Personal protective equipment when working on systems which pose an explosion hazard
The parts listed here apply in particular to safety when working on

systems which pose an explosion hazard.
If work is carried out in areas with a potentially explosive atmosphere,

the following items of equipment are required as an absolute mini­mum:

 Suitable clothing (risk of a build-up of electrostatic charge)
 Suitable tools (compliant with EN 1127)
 A suitable gas warning device which is calibrated for the existing

vapor-air mixture (work should only be performed at a concentra-

1

tion of 50 % below the lower explosion limit)

 Measuring device for determining the oxygen content of the air

(Ex/O meter)

2.5 Basic hazards
DANGER:

From electric current
When working on the opened leak detector, it must be disconnected

from the power supply unless otherwise stated in the documentation.
Comply with the relevant regulations for electrical installations, explo-

sion protection (e.g. EN 60 079-17) and accident protection regula­tions.

CAUTION:

Through moved parts
If work is carried out on the leak detector, switch off the power supply.

DANGER:

From explosive vapor-air mixtures
There may be explosive steam-air mixtures in the leak detector and in

the connection lines.
The absence of gas must be established before carrying out work.
Comply with explosion protection regulations, such as the German

BetrSichV (or the Directive 1999/92/EC and the resulting laws in the
respective member states) and/or others.

DANGER:

When working in shafts
The leak detectors are fitted outside the manhole shafts. The pneu-

matic connection is typically made in the manhole shaft. The shaft
should therefore be entered for the installation.

Before entry, the appropriate protection measures must be installed
and the absence of gas and sufficient oxygen must be ensured.

1

Other percentages may be applicable according to national, regional or plant-specific regulations.

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3. Technical data of the leak detector

3.1 General Data

Dimensions and drilling template see Sec. 12.3
Weight 8.3 kg
Storage temperature range -40°C to +60°C
Use temperature range -40°C to +60°C
Buzzer volume Summer > 70 dB(A) in 1 m
Protection rating of the housing IP54

3.2 Electrical data

Supply voltage 100…240 VAC, 47-63 Hz

Power consumption 50 W (including heating)

Technical Data

optionally: 24 VDC

3.3 Ex data

3.4 Switching values

Terminals 5, 6, external signal: max. 24 VDC; 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: max. 10 A, 1500 A breaking

capacity

Overvoltage category: 2

Important:

only pneumatic part II 1/2G Ex c IIB3 T4 Ga/Gb

Type Alarm ON,

at the latest at:
34 -34 mbar -100 mbar -250 mbar
80 -80 mbar -140 mbar -400 mbar

230 -230 mbar -360 mbar -650 mbar
255 -255 mbar -380 mbar -650 mbar
330 -330 mbar -450 mbar -700 mbar

Pump OFF,
not more than:

Functional capabil­ity* of the IS** for

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410 -410 mbar -540 mbar -750 mbar
500 -500 mbar -630 mbar -850 mbar
570 -570 mbar -700 mbar -900 mbar

Special switching values can be agreed between the customer and
SGB.

* Lower values can be agreed, but an underpressure valve must then
be integrated into the leak detector.

** interstitial space

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Technical Data

3.5 Field of application

3.5.1 Vessel
a) Single-walled (underground/above-ground), cylindrical tanks with

leak protecting lining (LPL) or leak protecting jacket (LPJ) and the
suction line up to the low point

Usage limits: none in relation to density and diameter

b) Double-walled, horizontal cylindrical tanks (underground/above-

ground) (e.g. DIN 6608-2, 6616 or DIN EN 12 285-1-2)

- as with a), but without suction line to low point

- as with c), but without suction line to low point

- as with d), but without suction line to low point
Usage limits:

H

Density of

the material

being stored

3

[kg/dm

]

Vessel height or height from low point of the

max.

pipe to the node point

2

[m]

230 255 330 410 500 570

0.8 2.6 2.9 3.8 4.8 6.0 6.9

0.9 2.3 2.6 3.4 4.3 5.3 6.1

1.0 2.0 2.3 3.1 3.9 4.8 5.5

1.1 1.9 2.1 2.8 3.5 4.4 5.0

1.2 1.7 1.9 2.6 3.2 4.0 4.6

1.3 1.6 1.8 2.4 3.0 3.7 4.2

1.4 1.5 1.6 2.2 2.8 3.4 3.9

1.5 1.4 1.5 2.0 2.6 3.2 3.7

1.6 1.3 1.4 1.9 2.4 3.0 3.4

1.7 1.2 1.4 1.8 2.3 2.8 3.2

1.8 1.1 1.3 1.7 2.2 2.7 3.1

1.9 1.1 1.2 1.6 2.0 2.5 2.9

For underground systems at least density 1 is to be assumed.
In above-ground systems, the leak detector is to be fitted above

the top of the tank.

c) Double-walled (including single-walled with leak protecting lining or

leak protecting jacket) cylindrical standing vessels or tanks with
curved floors (underground/above-ground) with a suction line up to
the low point (DIN 6618-2: 1989)

2

Node point is the junction of the suction and measuring line with a vacuum leak detector for pipes. This can

also be in the assembly kit or a manifold.

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Usage limits:

Technical Data

Diameter

[mm]

1600

2 000

2500

2900

Height

[mm]

Max. density of the material being

stored

3

[kg/dm

]

34 230 255 330 to 570

 2,820  1.9  1.9  1.9  1.9

 3,740  1.6  1.9  1.9  1.9

 5,350  1.6  1.9  1.9  1.9

 6,960  1.6  1.9  1.9  1.9

 5,400  1.4  1.9  1.9  1.9

 6,960  1.4  1.9  1.9  1.9

 8,540  1.4  1.9  1.9  1.9

 6,665  1.0  1.9  1.9  1.9

 8,800  1.0  1.9  1.9  1.9

 8,400  0.9  1.9  1.9  1.9

 9,585  0.9  1.9  1.9  1.9

 12,750  0.8  1.2  1.2  1.6

 15,950

-

 1.0  1.0  1.2

d) Right-angle or cylindrical tanks or tubs with flat floors (double-

walled or LPL or LPJ) with suction line to low point

Density of

the material

H

[m]

max.

being stored

[kg/dm

3

]

34 230 255 330 410 500 570

0.8 7.5 17.3 19.1 23.4 23.8 24.5 24.2

0.9 6.6 15.3 17.0 20.8 21.1 21.8 21.5

1.0 6.0 13.8 15.3 18.7 19.0 19.6 19.4

1.1 5.4 12.6 13.9 17.0 17.3 17.8 17.6

1.2 5.0 11.5 12.8 15.6 15.8 16.4 16.2

1.3 4.6 10.6 11.8 14.4 14.6 15.1 14.9

1.4 4.3 9.9 10.9 13.4 13.6 14.0 13.8

1.5 4.0 9.2 10.2 12.5 12.7 13.1 12.9

1.6 3.7 8.6 9.6 11.7 11.9 12.3 12.1

1.7 3.5 8.1 9.0 11.0 11.2 11.5 11.4

1.8 3.3 7.7 8.5 10.4 10.6 10.9 10.8

1.9 3.1 7.3 8.1 9.8 10.0 10.3 10.2

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Technical Data

3.5.2 Pipes/tubes
In the design manufactured either in the plant or on-site
Usage limits: in accordance with the Table in Sec. 3.5.1 in b), where

the height between the low point of the interstitial space and the node
point (junction of the suction line and measuring line, generally in the
assembly kit or manifold, see also 5.7.4 ff) is to be used instead of the
tank diameter.

- Suction lines: The alarm underpressure must be at least 30 mbar

greater than the max. underpressure in the inner pipe at the high­est point of the interstitial space

- Pressureless lines such as filling lines

- Pressure-controlled pipelines with up to 5 bar overpressure (only if

flash point > 60 °C), see also chap. 2.1.

- In special application cases (individual pressureless pipeline, gra-

dient to a point) the VLXE 34 design can also be used.

3.5.3 Monitorable fluids

- For Germany: with usability certificate from construction oversight

authority

Note: Double-walled fittings may also be integrated into the pipeline.
Double-walled fittings can also be monitored for themselves with this
leak detector. The installation examples for pipes are to be applied
analogously.

Water-polluting liquids with a flashpoint ≤ 60°C (for Germany the limit
is 55°C in accordance with TRGS 509 and 751), such as fuels and
combustibles.

The following conditions also apply:

- The materials used must be resistant to the liquids being moni-

tored.

- Water-polluting liquids with flashpoint ≤ 60 °C (for Germany the

1

limit is 55 °C in accordance with TRGS 509 and 751)

and flash­point > 60 °C (for Germany the limit is 55 °C in accordance with
TRGS 509 and 751) with possible explosive vapor-air mixtures
(e.g. due to outgassing).
These possible explosive vapor-air mixtures must be heavier than
air and classifiable into Explosion group IIA or IIB as well as in
temperature class T1 to T3, such as fuel e.g. (petroleum).

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- If different water-polluting liquids are being conveyed in single
pipes and monitored with a leak detector, these liquids must not
negatively influence one another and the mixture must not lead to
chemical reactions.

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4. Design and function

4.1 Design

69

Design and function

76

75

139

102

91

60

18

20

21

Interior view with:

18 Detonation flame arrester
20 Three-way valve in suction line
21 Three-way valve in measuring line
60 Vacuum pump
69 Buzzer
75 Display board
76 Main circuit board
91 Heater
102 Pressure sensor
139 Membrane keyboard

4.2 Normal operation

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The vacuum leak detector is connected to the interstitial space
through the suction, measurement and connection line(s). The under­pressure generated by the pump is measured by a pressure sensor
and regulated.

When the operating underpressure (Pump OFF) is reached the pump
is switched off. Due to small leaks in the leak indication system which
are unavoidable, the underpressure will slowly start to fall. When the
Pump ON switching value is reached, the pump is switched on and

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Design and function

4.3 Air leak

the interstitial space is evacuated until the operating underpressure
(Pump OFF) is reached.

Depending on the level of tightness and temperature fluctuation in the
overall system, the underpressure alternates between the Pump OFF
switching value and the Pump ON switching value, with short pump
running times and longer down times.

If an air leak occurs (in the outer wall or inner wall, above the fluid
level), the underpressure pump switches on, in order to restore the
operating underpressure. If the volume of air flowing in through the
leak exceeds the limited conveying quantity of the pump, the pump
continues to run.

Increasing leak rates lead to a further drop in underpressure (with
pump running) until the switching value “Alarm ON” is reached. Visual
and audible alarm signals are then triggered.

4.4 Liquid leak

If there is a liquid leak, liquid penetrates the interstitial space and col­lects at the bottom of the interstitial space.

The liquid entering lowers the underpressure, the pump is switched
on and evacuates the interstitial space(s) until the operating under­pressure is reached. This process is repeated multiple times until the
liquid stop valve in the suction line is closed.

Due to the underpressure still existing on the measuring line side, fur­ther fluid leaks will be sucked into the interstitial space, the measuring
line and, if appropriate, the pressure compensation vessel. This leads
to a decline in underpressure until the “Alarm OFF” pressure is
reached. Visual and audible alarm signals are then triggered.

Note: A liquid sensor connected to a magnetic valve can optionally be
used instead of a liquid stop valve. The liquid alarm is then triggered
by the liquid’s contact with the sensor.

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4.5 Display and control elements

4.5.1 Display
Signal

lamp

OPERA­TION:

green

ALARM:

red

ALARM
2:

yellow

Design and function

Operat­ing sta­tus

Alarm, under­pressure below
“Alarm ON”

Alarm
probe

Magnetic
valve fault

Device
fault

ON ON ON ON ON

OFF ON (flashing)

3

OFF

ON

(flashing)

ON4

ON

OFF OFF

(flash-

ON OFF

ing)

4.5.2 Function: "Switch off audible alarm signal"
Briefly press the "Mute" button once. The audible alarm signal is then

switched off and the red LED flashes.
Pressing the button again switches on the audible signal.
This function is not available in normal operation and for malfunc-

tions.

4.5.3 Function: "Test visual and audible alarm signal"
Press the "Mute" button and keep it pressed (approx. 10 seconds).

The alarm signal is triggered until the button is released again.
This test is only possible if the pressure in the system has exceeded

the "Alarm OFF" pressure level.

3

(flashing) is always active when acknowledged external signal is active.

4

The “Audible alarm” button has no function, meaning the acoustic signal cannot be stopped.

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