SGB DLR-GS Operator's manual

Documentation
Pressure Leak Detector DLR-GS
Please read instructions prior to commencing any work
As of: 08/2020
Item no.: 604302

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Overview of the design variants
DLR pressure leak detectors are available in different versions that are described more precisely
by the suffix characters. The levels of availability and the possible combinations depend on the de-
vice. Please contact our sales team. Phone [phone], email [e-mail]
DLR- … .. P M N LE/LG Si
„Service indication”: integrated service
indicator (LED) with an adjustable service
period
Equipped with data transfer module (DTM)
for the LOD-Service.
Data transfer via Leak detection-Online-Di-
agnostic with Ethernet-module (LE) or GSM-
module (LG)
„N/ Feed required“: The leak detector indicates
by means of a diode that the pressure in the in-
terstitial space has decreased and that the
pressure must be built up again
„Manometer/ Pressure gauge“: The leak detector
is equipped with a digital pressure display in the
housing cover
„Protected“: Construction of the leak detector in a
weatherproof housing
„..“ = „Numerical value“ for the alarm-vacuum of the leak
detector.
„G = Gas (bottle)“: A pressure gas bottle is used for pressure
generation, usually nitrogen
„P = Pump“: A pump integrated in the leak detector is used for
pressure generation
„GS = Gas (bottle) static“: A static pressure generator must
be brought to the site since the leak detector does not have a
pump or automatic feed mechanism
„DLR/ Pressure Leak Detector Pipe“: The leak detector operates
with overpressures towards the atmosphere and is designed for ap-
plication on double-walled pipes
Design variations

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Table of Contents
1.General................................................................................. 5
1.1Information...................................................................5
1.2Explanation of Symbols ............................................... 5
1.3Limitation of Liability ....................................................5
1.4Copyright .....................................................................5
1.5Warranty Conditions ....................................................6
1.6Customer Service ........................................................6
2.Safety ...................................................................................7
2.1Intended Use ...............................................................7
2.2Obligation of the Operating Company .........................7
2.3Qualification ................................................................. 8
2.4Personal Protective Equipment (PPE).........................8
2.5Fundamental Hazards .................................................9
3.Technical Data of the Leak Detector .................................10
3.1General Data ............................................................... 10
3.2Electrical Data..............................................................10
3.3Switching Values ......................................................... 11
3.4Field of Application ......................................................12
4.Design and Function...........................................................14
4.1Design..........................................................................14
4.2Normal Operating Condition ........................................16
4.3Function in Case of Leaks ........................................... 16
4.4Overpressure Valve .....................................................16
4.5Displays and Controls..................................................17
5.Mounting the System..........................................................18
5.1Basic Instructions.........................................................18
5.2Leak Detector ..............................................................18
5.3Selecting the Pressure Gas Bottle and the Pressure
Reducer .......................................................................19
5.4Setting up the Pressure Gas Bottle and Mounting
the Pressure Reducer..................................................19
5.5Pneumatic Connection Lines, Requirements...............19
5.6Completing Pneumatic Connections............................19
5.7Electrical Cables ..........................................................20
5.8Electrical Wiring Diagram ............................................21
5.9Installation Examples...................................................23
6.Commissioning ...................................................................26
6.1Commissioning the Pressure Gas Bottle .....................26
6.2Commissioning the Leak Detector...............................26
6.3Changing the Pressure Level ......................................27
7.Functional Check and Maintenance..................................28
7.1General ........................................................................28
7.2Maintenance ................................................................28
7.3Functional Check .........................................................28
Table of Contents

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8.Alarm (Malfunction).............................................................31
8.1Alarm............................................................................31
8.2Malfunction...................................................................31
8.3How to Behave.............................................................31
9.Spare Parts ..........................................................................32
10.Accessories .........................................................................33
11.Disassembly and Disposal.................................................34
11.1Disassembly.................................................................34
11.2Disposal .......................................................................34
12.Appendix..............................................................................35
12.1Dimensions and Drilling Pattern, Plastic Housing........35
12.2Dimensions and Drilling Pattern, Stainless Steel
Housing for Installation Outdoors (IP 54).....................36
12.3Declaration of Conformity.............................................37
12.4Declaration of Performance .........................................38
12.5Manufacturer’s declaration of compliance....................38
12.6Certification TÜV Nord .................................................39
Table of Contents

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1. General
1.1 Information
These instructions provide important notes on using the leak detector
DLR-GS. Complying with all safety instructions and guidelines is a
prerequisite 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 com-
piled considering the applicable norms and regulations, the state of
the art and our longstanding experience.
SGB does not assume any liability in case of:
Noncompliance with these instructions
Unintended use
Use of unqualified personnel
Unauthorized modifications
Connection to systems not approved by SGB
1.4 Copyright
The contents, texts, drawings, images and other representations are
copyrighted and subject to industrial property rights. Any misuse is
punishable.

General


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1.5 Warranty Conditions
We provide warranty for the leak detector DLR-GS for a period of 24
months from the day of installation on site in accordance with the
General Terms & Conditions.
The maximum warranty period is 27 months from our date of sale.
Warranty is subject to submission of the functional/test report on ini-
tial commissioning by qualified personnel.
Stating the serial number of the leak detector is required.
The obligation of warranty shall cease to exist in case of
- inadequate or improper installation
- unintended use
- modifications/repairs without the manufacturer's consent.
Our warranty does not include parts, which may be perished prema-
ture due to their consistence or category of usage (e.g. pumps,
valves, gaskets, etc.). Furthermore, we are not liable for defects or
corrosion damages caused by humid or inappropriate installation en-
vironments.
1.6 Customer Service
Our customer service is available for any inquiries.
For information on contacts please refer to our website sgb.de/en or
the label of the leak detector.
General

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2. Safety
2.1 Intended Use
For double-walled pipes/fittings installed underground or indoors
only.
The leak detector alarm pressure must be at least 1 bar higher
than the maximum feed pressure in the product-transporting pipe.
Grounding in accordance with valid regulations1.
Tightness of the leak detection system according to section 7.3.4.
Leak detector installed outside of the explosive area.
Lead-throughs for connection lines into and out of the manhole
chamber must be sealed gas-tight.
Leak detector (electric) cannot be turned off.
Use of the leak detection medium compressed air only with con-
veyed media with flash point > 60°C (> 55°C for Germany accord-
ing to TRGS 509 and 751).
Use of the leak detection medium nitrogen with conveyed media
with flash point > 60°C and ≤60°C if the interstitial space is zone 2
(> 55°C and ≤55°C for Germany according to TRGS 509 and
751).
Section 3.4.5 must be complied with.
Any claims arising from misuse are excluded.
2.2 Obligation of the Operating Company
The leak detector DLR-GS is used in a commercial environment. The
operating company is therefore subject to statutory occupational
safety obligations.
In addition to the safety instructions in this documentation, all applica-
ble safety, accident prevention and environmental regulations must
be adhered to. In particular:
- Compiling a risk assessment and implementing its results in a di-
rective
- Performing regular checks as to whether the directive is in compli-
ance with the current standards
- The directive includes, among others, how to react to an alarm that
might arise
- Arranging for an annual functional check
1For Germany: e.g. EN 1127
WARNING!
Danger from
misuse
WARNING!
Danger in case
of incomplete
documentation
Safety

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2.3 Qualification
The personnel must be capable of independently recognizing and
avoiding potential risks based on their qualifications.
Companies commissioning leak detectors should have completed re-
spective training with SGB, through SGB or its authorized representa-
tive.
National guidelines must be adhered to.
For Germany:
Technical service qualification for installation, commissioning and
maintenance of leak detection systems
2.4 Personal Protective Equipment (PPE)
Personal protective equipment must be worn during work.
- Wear necessary protective equipment for the relevant work
- 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
2.4.1 Personal Protective Equipment working with systems that may be subject to risk of explo-
sion
The parts listed here refer in particular to safety when working with
systems that may be subject to risk of explosion.
WARNING!
Danger to hu-
mans and the en-
vironment in case
of inadequate
qualification
Safety

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If work is performed in areas in which an explosive atmosphere must
be expected, the minimum required equipment is as follows:
Suitable clothing (risk of electrostatic charge)
Suitable tools (in accordance with 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)2
Measuring equipment to determine the oxygen content in the air
(Ex/O-meter)
2.5 Fundamental Hazards
DANGER
From electric current
When working on the leak detector, it must be disconnected from the
power supply unless stated otherwise in the documentation.
Comply with relevant regulations regarding electric installation,
explosion protection (e.g. EN 60 079-17), if necessary, and accident
prevention.
DANGER
From explosive vapor-air mixtures
Ensure there is no gas present prior to performing work
Comply with explosion regulations, e.g. BetrSichV (and/or directive
1999/92/EC and the laws of the respective member states resulting
therefrom) and/or others.
DANGER
From working in shafts
The leak detectors are mounted outside the manhole chambers.
Pneumatic connection is usually performed inside the manhole cham-
ber. Therefore, the chamber must be entered for mounting.
Before entering, the corresponding protective measures must be
taken and it must be ensured that no gas and sufficient oxygen are
present.
2Other manufacturers' or countries' regulations may provide different percentages.
Safety

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3. Technical Data of the Leak Detector
3.1 General Data
Dimensions and drilling pattern: see sections 12.1 and 12.2
Weight: 2.1 kg (plastic housing)
6.3 kg (stainless steel housing)
Storage temperature range: -40°C to +70°C
Operating temperature range: 0°C to +40°C (plastic housing)
-40°C to +60°C (stainless steel
housing incl. heating)
Housing protection class: IP 30 (plastic housing)
IP 54 (stainless steel housing)
3.2 Electrical Data
Power supply 100 … 240 V AC
optional: 24 V DC
Power input: 10 W (without heating)
28 W (incl. heating at 20°C)
Terminals 5, 6 (external signal): max. 24 V DC; max. 300 mA*
Terminals 11…13 (voltage-free): DC ≤25 W or AC ≤50 VA
Terminals 17…19 (voltage-free): DC ≤25 W or AC ≤50 VA
Fuse protection: max. 10 A
Overvoltage category: 2
* With Ethernet board max. 150 mA
Technical Data

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3.3 Switching Values
The following abbreviations are used in the table:
pOMaximum operating pressure in the inner pipe (feed pressure + dynamic
pressure + pressure due to geodetic height differences)
pAON Switching value "Alarm ON"; the alarm will be triggered at this pressure level
at the latest
pSETPT Pressure setpoint which should be built up according to the manufacturer’s
recommendation. Note: there is no display indication when this pressure is
reached.
This setting can be varied, in which case the following must be noted:
- Upwards: the test pressure must be at least 1.3 times higher
- Downwards: the alarm pressure is reached considerably more quickly
pTEST Minimum test pressure of the interstitial space
pPR Set pressure on the pressure reducer (must be adjusted in some cases, ac-
cording to the pressure setpoint)
With the function “Feed required” display, this pressure value is about 1 bar
higher than the alarm pressure.
Further switching values:
pAOFF Switching value "Alarm OFF"; the alarm will be deactivated if this value is
exceeded
type 1 to 8 approx. 250 mbar
type 10 to 16 approx. 500 mbar
3Switches 1 to 9 for determining the pressure level
Type DLR-GS pO
[bar]
pAON
[bar]
pSETPT
[bar]
Switch position of
dip switch pTEST
[bar]
pPR
[bar]
1 pressureless > 1 5
3
> 6,5 5
2 < 1 > 2 6 > 8 6
3 < 2 > 3 7 > 9 7
4 < 3 > 4 8 > 10 8
6 < 5 > 6 10 > 13 10
8 < 7 > 8 12 > 16 12
10 < 9 > 10 14 > 18 14
13 < 12 > 13 17 > 22 17
16 < 15 > 16 20 > 26 20
Special values agreed between
SGB and customer
Technical Data

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3.4 Field of Application
3.4.1 Interstitial space requirements
Proof of pressure resistance of the interstitial space (see section
3.3, column "pTEST" minimum test pressure of the interstitial space)
Proof of suitability of the interstitial space (for Germany: proof of
usability from construction authority).
Sufficient passage in the interstitial space for the leak detection
medium (air/nitrogen)
Tightness of the interstitial space according to this documentation.
The number of interstitial spaces to be monitored depends on the
total interstitial space volume. According to EN 13160, 10 m3may
not be exceeded. To be able to test the tightness of the interstitial
space, it is recommended not to exceed 4 m3.
The pipeline length (per duct) to be monitored should not exceed
2500 m and must correspond with the specifications for the pipe
permit.
3.4.2 Pipes
Double-walled pipes made of metal or plastic, in factory or on-site
construction.
For Germany: Additional requirements may result from the respec-
tive permits.
ONLY for applications without temperature variations of more than
10°C (e.g. double-walled pipes installed underground or indoors
– no hot media).
3.4.3 Fittings
Double-walled fittings made of metal or plastic in factory or on-site
construction.
For Germany: with proof of usability from construction authority,
unless it is part of the pipe permit.
ONLY for applications without temperature variations of more than
10°C (e.g. double-walled pipes installed underground or indoors
– no hot media).
3.4.4 Conveyed product
Liquids hazardous to water, even with a flash point of ≤60°C (for
Germany ≤55°C according to TRGS 509 and TRGS 751). Chapter
3.4.5 is to be observed.
The conveyed product may not react with the leak detection me-
dium.
Technical Data

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3.4.5 Interaction between interstitial space, leak detection medium and operating mode
Regardless whether there is permeation in the interstitial space or
not, the leak detection medium nitrogen is to be used for all applica-
tions if the goods to be conveyed have a flash point ≤60°C (≤55°C
for Germany according to TRGS 509 and TRGS 751).
This specification is based on a risk evaluation according to the di-
rective 2014/34/EU (explosion directive). The risk evaluation was per-
formed based on the table in section 3.3 (informative) for EN 13160.
If the evaluation of the device categories has different results due to
operational regulations or for any other reasons, the use of the leak
detector must be checked separately.
Technical Data

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4. Design and Function
4.1 Design
Interior view of plastic housing with:
01 Signal lamp "Alarm", red
09 Signal lamp "Operation", green
23 Signal lamp "Refilling required", yellow
29 Button "Commissioning" (filling)
69 Buzzer
71 “Mute” Button
75 Display board
76 Main board
102 Pressure sensor
140 Contact for serial data transfer
75
102
09
01
71
69
23
76
140
Design and Function

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Interior view of stainless-steel housing, weather-protected, with:
44 Solenoid valve
69 Buzzer
70-1 Overpressure valve (interstitial space)
70-2 Overpressure valve (supply)
75 Display board
76 Main board
102 Pressure sensor
140 Contact for serial data transfer
141 Keypad terminal strip
144 Temperature switch, frost protection
75
102
69
76
140
141
144
Design and Function

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The pressure leak detector DLR-GS monitors both walls of the dou-
ble-walled system for leaks. The monitoring pressure during operation
is higher than any pressure on the inner or outer wall, so that leaks
will be indicated by a pressure drop.
Inert gas, air from a pressure gas bottle or from a pressure gas sys-
tem can be used as leak detection media. If air is used, it must be
dried to a relative humidity of less than 10%.
The current pressure is shown on the display in mbar/bar or PSI4:
Values of less than 150 mbar or less than 2.18 PSI will not be dis-
played.
Values of up to 990 mbar will be displayed in mbar and without
decimal.
Values from 1 bar are displayed in bar with two decimals and from
10 bar with one decimal.
Values in PSI are displayed with one or two decimals.
4.2 Normal Operating Condition
The normal operating condition is achieved during the initial operation
through pressure buildup to the operating pressure, generally with a
mobile pressure tank.
The existing pressure in the interstitial space is monitored with a pres-
sure sensor in the leak detector. Any minor leaks will lead to a fall in
pressure. The result of this is that the requirements for the impermea-
bility of the interstitial space(s) and the connection(s) must be set very
high to assure trouble free operation for one year.
4.3 Function in Case of Leaks
If there is a leak in the inner or outer wall, gas will leak from the inter-
stitial space. The pressure drops.
An optical and audible alarm will be triggered when the alarm pres-
sure is reached, which will open the voltage-free contacts.
Optionally, an additional relay can be used to establish voltage-free
contacts when the specified “Refilling required” pressure is not
reached. The pressure value for “Refilling required” is approx. 1 bar
above the "Alarm ON” switching value.
4.4 Overpressure Valve
An overpressure valve is not provided in the leak detector, but it can
be installed if the application requires it. (Please consult with the man-
ufacturer).
4The change of the bar and PSI settings is performed at the factory. This change can also be performed on
site following coordination with the manufacturer.
Design and Function

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4.5 Displays and Controls
4.5.1 Display
Signal lamps
Operating Con- dition Refilling acti- vated or re- quired
A
larm condition
A
larm, audible
alarm acknow- ledged Device malfunc- tion
OPERATION:
green ON ON ON ON ON
ALARM: red OFF OFF ON BLINK-
ING
ON
REFILLING:
yellow OFF ON ON ON OFF
4.5.2 Function "Turn off audible alarm signal"
Shortly press "Mute" button once, audible signal turns off, the red
LED blinks.
Pressing the button again will turn the audible signal on.
This function is not available during normal operating conditions and
malfunctions.
4.5.3 Function "Testing the optical and audible alarm signal"
Press and hold the "Mute" button (about 10 seconds). The alarm will
be triggered until the button is released.
This inquiry is only possible if the pressure in the system has ex-
ceeded the "Alarm OFF" pressure.
Design and Function

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5. Mounting the System
5.1 Basic Instructions
Prior to commencing work, the documentation must be read and
understood. In case of ambiguities, please refer to the manufac-
turer.
The safety instructions in this documentation must be adhered to.
Only qualified service companies may be used for installation.
Comply with relevant regulations for prevention of accidents.
Lead-throughs for pneumatic and electric connection lines, through
which the explosion atmosphere can carry over, must be sealed
gas-tight.
Comply with explosion regulations (if required), e.g. BetrSichV
(and/or directive 1999/92/EC and the laws of the respective mem-
ber states resulting therefrom) and/or others.
Compliance with the relevant traffic regulations is required when
transporting pressure gas bottles to and from the construction site.
The pressure gas bottle must be protected from falling over at the
construction site.
If nitrogen is used, sufficient ventilation must be provided if com-
missioning/operation is performed in enclosed spaces. Attach in-
formation sign.
Provide a test valve at the end facing away from the leak detector
at the end of the pipe(s)/fitting(s).
Before entering inspection chambers, the oxygen content must be
tested and the inspection chamber flushed if necessary.
If metallic connection lines are used, it must be ensured that the
power supply grounding is on the same potential as the pipe to be
monitored.
Notes on personal protective equipment are provided in chapter
2.4.
5.2 Leak Detector
(1) Generally mounted on walls with plugs and screws.
(2) In a dry room, or outdoors in a suitable housing.
(3) If mounted in a protective box: additional external signal or alarm
forwarding via voltage-free contacts to a switchboard or similar
device.
(4) NOT in potentially explosive areas.
(5) Dimensions of housings and drilling patterns are illustrated in Ap-
pendix 12.1 and 12.2, respectively.
Mounting

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5.3 Selecting the Pressure Gas Bottle and the Pressure Reducer
(1) The pressure reducer must have an integrated overpressure
valve.
(2) The range of settings for the pressure reducer to be used must
be selected in correspondence with the application or the pres-
sure to be set. (see section 3.3).
(3) The maximum pressure setting on the pressure reducer should
not exceed the test pressure for the interstitial space
(SGB recommendation).
5.4 Setting up the Pressure Gas Bottle and Mounting the Pressure Reducer
(1) Set up and secure pressure gas bottle, e.g. using a bracket and
safety chain intended for this purpose.
(2) Close safety chain.
(3) Remove protective cover and mount pressure reducer to bottle.
(4) Close shut-off valve on the pressure reducer.
5.5 Pneumatic Connection Lines, Requirements
Pressure resistance of the metal (generally Cu) or plastic pipes
must at least correspond with the test pressure in the interstitial
space. Also applies to fittings and screwed connections. Note tem-
perature range, especially when using plastic.
Inside clearance
at least 4 mm with inert gas as leak detection medium
at least 6 mm with air as leak detection medium
50 m should not be significantly exceeded, but if this happens: In-
stall pipe with greater inside clearance using transition pieces.
The full cross section must be maintained. Do not push in or bend5.
Install metal or plastic pipes underground or plastic pipes above-
ground outdoors in protective pipes.
Seal the protective pipe gas-tight and protect from moisture.
Avoid build-up of electrostatic charges (e.g. during pulling of lines).
5.6 Completing Pneumatic Connections
5.6.1 Between pressure reducer and leak detector
(1) Select suitable test equipment to connect the pressure re-
ducer to the leak detector. Recommendation: Use the test
equipment SGB item no.: 115520
(2) Mount the test equipment with pressure reducer at the pres-
sure gas bottle.
(3) Connect the test equipment to the leak detector.
5
If necessary, install commercial fittings for plastic pipes (specified bending radii).
Mounting

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5.6.2 Between leak detector and interstitial space, test valves
(1) Select and install suitable pipe.
(2) During installation of the tube/pipe, ensure again that the tubes
are protected against damage when the manhole chamber is en-
tered.
(3) Complete the relevant connection (according to the illustrations in
the following images)
(4) According to the specifications of the manufacturer of the pipe/in-
terstitial space
5.6.2.1 Flanged screw connections (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 noticeable
(6) Final assembly: Tighten by another ¼ turn
5.6.2.2 Clamping ring screw connection for metal and plastic pipes
(1) Insert support sleeve (only plastic pipe) into the pipe end
(2) Insert the pipe (with support sleeve) as far as it will go
(3) Tighten nut of screw connection by hand to the resistance; then
turn further 1¾ turns with the wrench
(4) Release nut
(5) Tighten nut by hand until stronger resistance
(6) Final assembly of the screw connection by tightening ¼ turn
5.6.2.3 Quick screw connections for PA tubing
(1) Cut PA tube 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)
5.7 Electrical Cables
Power connection:
- 2.5 mm2without ferrule
- 1.5 mm2with ferrule and plastic collar
Voltage-free contacts and external signal:
- 1.5 mm2without ferrule
- 0.75 mm2with ferrule and plastic collar
Mounting