SGB DLR-P Series Operator's manual

Documentation
Pressure leak detector DLR-P
Please read instructions before starting any work
Issued: 07/2020
Art. no.: 604422

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Table of Contents 1. General .............................................................................4
1.1 Information................................................................4
1.2 Explanation of Symbols.............................................4
1.3 Limitation of Liability..................................................4
1.4 Copyright ..................................................................4
1.5 Warranty Conditions..................................................5
1.6 Customer Service .....................................................5
2. Safety................................................................................6
2.1 Intended Use.............................................................6
2.2 Obligation of the Operating Company.......................6
2.3 Qualification..............................................................7
2.4 Personal Protective Equipment (PPE).......................7
2.5 Fundamental Hazards...............................................8
3. Technical Data of the Leak Detector...............................9
3.1 General Data.............................................................9
3.2 Electrical Data...........................................................9
3.3 Switching Values.......................................................9
3.4 Field of Application..................................................10
4. Design and Function......................................................12
4.1 Design.....................................................................12
4.2 Normal Operating Condition....................................16
4.3 Function in Case of Leaks.......................................16
4.4 Overpressure Valve ................................................17
4.5 Dry filter ..................................................................17
4.6 Displays and Controls.............................................17
5. Installing the System .....................................................20
5.1 Basic Instructions....................................................20
5.2 Leak Detector..........................................................20
5.3 Dry filter ..................................................................20
5.4 Pneumatic Connection Lines, Requirements...........21
5.5 Completing Pneumatic Connections .......................21
5.6 Electrical Cables.....................................................22
5.7 Electrical Wiring Diagram........................................22
5.8 Installation Examples..............................................24
6. Commissioning..............................................................30
6.1 Tightness Test ........................................................30
6.2 Commissioning the Leak Detector...........................30
7. Functional Check and Maintenance..............................32
7.1 General...................................................................32
7.2 Maintenance ...........................................................32
7.3 Functional Check....................................................32
8. Alarm (Malfunction) .......................................................36
8.1 Alarm ......................................................................36
8.2 Malfunction .............................................................36
8.3 How to Behave........................................................36
9. Spare Parts.....................................................................37
10. Accessories....................................................................38
Table of Contents

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11. Disassembly and Disposal............................................39
11.1 Disassembly ...........................................................39
11.2 Disposal..................................................................39
12. Appendix ........................................................................40
12.1 Dimensions and Drilling Pattern, Plastic Housing
with Pulsation Damper............................................40
12.2 Dimensions and Drilling Pattern, Stainless Steel
Housing with Pulsation Damper for Installation
Outdoors (IP 54), small housing or DLR-P devices
with pressure values < 3.0 ......................................41
12.3 Dimensions and Drilling Pattern, Stainless Steel
Housing with Pulsation Damper for Installation
Outdoors (IP 54), big housing or DLR-P devices
with pressure values > 3.0 ......................................42
12.4 Declaration of Conformity........................................43
12.5 Declaration of Performance.....................................44
12.6 Declaration of Compliance of the manufacturer.......44
12.7 Certifications TÜV Nord ..........................................45
Table of Contents

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1. General
1.1 Information
These instructions provide important notes on using the leak detector
DLR-P. 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 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
•Improper 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-P 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 trained 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
- improper use
- changes/repairs made 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 or the
label of the leak detector.
General

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2. Safety
2.1 Intended Use
•For double-walled pipe/fittings with an interstitial space that is suf-
ficiently pressure resistant
•The leak detector alarm pressure must be at least 1 bar higher
than the maximum feed pressure in the product-transporting pipe.
•Grounding/equipotential bonding in accordance with applicable
regulations
1
.
•Tightness of the leak detection system according to section 7.3.4.
•Leak detector installed outside of the explosive area.
•Lead throughs into and out of the manhole chamber for connection
lines must be closed gastight.
•Leak detector (electric) cannot be turned off.
•Based on the use of air as leak detection medium, the following
points must be observed for conveyed media with a flash point
≤ 60 °C (Germany ≤ 55°C according to TRGS 509 and 751):
oExplosive vapor-air mixtures must be assigned to temperature
code T1 to T3 and gas group II A or II B.
oThe inner wall must not be permeable for media that can lead to
the development of explosive vapor-air mixtures.
oIt must also be noted that in case of a leak in the inner pipe, air
is pressed into the conveyed product. This must be considered
when evaluating explosion protection of pumps/fittings along
the length of the pipe run.
•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-P is used in a commercial environment. The
operating company is therefore subject to statutory occupational safe-
ty 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:
- Compiling a risk assessment and implementing its results in a di-
rective
- Performing regular checks as to whether the directive is in com-
pliance with the current standards
- The directive includes, among others, how to react to an alarm
that might arise
- Arranging for an annual functional check
1
For 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 (PPE) on systems where explosion hazards can arise
The parts listed here refer in particular to safety when working with
systems that may be subject to risk of explosion.
If work is performed in areas in which an explosive atmosphere must
be expected, the minimum required equipment is as follows:
WARNING!
Danger to humans
and the environment
in case of inade-
quate qualification
Safety

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•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 of 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, explo-
sion protection (e.g. EN 60 079-17), if necessary, and accident pre-
vention.
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
chamber. Therefore, the chamber must be entered for mounting.
Before entering, the corresponding protective measures must be tak-
en and it must be ensured that no gas and sufficient oxygen are pre-
sent.
2
Other 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 Appendix, sections 12.1 to
12.3
Weight: 2.7 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)
Housing protection class: IP 30 (plastic housing)
IP 54 (stainless steel housing)
3.2 Electrical Data
Power supply 100 to 240 VAC, 50/60 Hz
optional: 24 VDC
Power input up to 2.0: 50 W
DLR-P 4.5 100 W
Terminals 5, 6, External signal: max: 24 VDC; 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
3.3 Switching Values
Type
DLR-P
pFD [bar]
pAE [bar]
pPA [bar]
PÜDV13[bar]
pPRÜF [bar]
1.1
< 0.1
> 1.1
< 1.45
1.6 0.07
2,0
1.5
< 0.5
> 1.5
< 1.9
2.2 0.10
2,5
2.0
< 1.0
> 2.0
< 2.4
2.7 0.10
3,0
2.3
< 1.3
> 2.3
< 2.8
3.1 0.10
3,5
2.5
< 1.5
> 2.5
< 2.9
3.2 0.10
3,5
3.0
< 2.0
> 3.0
< 3.4
3.8 0.10
4,2
3.5
< 2.5
> 3.5
< 4.4
5.3 0.20
≥ 6.5
4.5
< 3.5
> 4.5
< 5.5
6.3 0.20
7,5

Special switching values agreed to by
SGB and customers
3
The table lists the opening pressure for overpressure protection at which the volume flow of the pump is diverted. The
operating pressure (initial opening) is lower.
Technical Data

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pFD Max. feed pressure in inner pipe
pAE Switching value "Alarm ON"; the alarm will be triggered at this
pressure level at the latest
pPA Switching value “Pump OFF” (= operating pressure)
pÜDV1 Opening pressure for overpressure valve 1 (interstitial space)
The use of overpressure valves can be omitted if the test
pressure of the interstitial space is 3 bar (Type 1.1 and 1.5)
or 10 bar (Type 2.0 to 3.0).
pPRÜF Minimum test pressure of the interstitial space
Supplement to the table:
pAA Switching value "Alarm OFF"; the alarm will be deactivated if
this value is exceeded
The switching value “Alarm OFF” is approx. 100 mbar higher
than the switching value “Alarm ON” (pAA = pAE + ~100 mbar)
pPE Switching value “Pump ON”
The switching value “Pump ON” is approx. 100 mbar lower
than the switching value “Pump OFF” (pPE = pPA - ~100 mbar)
3.4 Field of Application
3.4.1 Interstitial space requirements
oProof of pressure resistance of the interstitial space (see section
3.3 switching values, table, column “pPRÜF” Minimum test pressure
of the interstitial space)
oProof of suitability of the interstitial space (for Germany: proof of
usability from construction authority).
oSufficient passage in the interstitial space for the leak detection
medium air.
oTightness of the interstitial space according to this documentation.
oThe 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 2
500 m and must correspond with the specifications for the pipe per-
mit.
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 respective
permits.
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, un-
less it is part of the pipe permit.
Technical Data

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3.4.4 Conveyed product
oLiquids hazardous to water with a flash point of > 60°C (Germany:
> 55 °C according to TRGS 509 and 751)
oLiquids hazardous to water with a flash point of ≤ 60 °C (Germany
≤ 55 °C according to TRGS 509 and 751) ONLY for double-walled
pipes/fittings which have a feed side wall that is impermeable.
For pipes/fittings that are permanently filled with liquids, make sure
that the product feeding equipment (pumps...) is suitable for zone
0, because air will be pressed into the product in the case of a
leak.
oThe conveyed product may not react with the leak detection medi-
um.
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
17 Overpressure pump
62 Check valve
69 Buzzer
70 Overpressure valve (interstitial space)
71 “Mute” button
75 Display board
76 Main board
102 Pressure sensor
140 Contact for serial data transfer
75
17
09
62
01
71
69
76
102
70
140
Design and Function

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Interior view of stainless-steel housing, weather-protected, with:
17 Overpressure pump
20 Three-way valve in the pressure line
21 Three-way valve in measuring line
62 Check valve
69 Buzzer
70 Overpressure valve (interstitial space)
75 Display board
76 Main board
102 Pressure sensor
140 Contact for serial data transfer
141 Keypad connection
144 Temperature switch, frost protection
Design and Function
75
62
69
76
102
21
140
141
144
17
70
20

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Interior view of stainless-steel housing with LOD for DLR-P devices with
pressure values < 3.0:
17 Overpressure pump
20 Three-way valve in the pressure line
21 Three-way valve in the measuring line
62 Check valve
69 Buzzer
70 Overpressure valve (interstitial space)
75 Display board
76 Main board
102 Pressure sensor
140 Contact for serial data transfer
141 Keypad connection
144 Temperature switch, frost protection
149 Data transfer module (DTM)
75
62
69
76
102
21
140
141
144
17
70
20
149
Design and Function

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Interior view of stainless-steel housing for DLR-P devices with pressure val-
ues > 3.0:
17 Overpressure pump
20 Three-way valve in the pressure line
21 Three-way valve in the measuring line
62 Check valve
64 Dust filter
69 Buzzer
70 Overpressure valve (interstitial space)
75 Display board
76 Main board
102 Pressure sensor
140 Contact for serial data transfer
141 Keypad connection
Design and Function
75
64
62
69
76
102
21
140
141
17
70
20

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The pressure leak detector DLR-P monitors both walls of the double-
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.
Air is used as leak detection medium. It is dried to a relative humidity
of less than 10 % by the dry filter in the vacuum line. Used dry filter
fillings must be regenerated or exchanged.
The current pressure is shown on the display in mbar/bar or PSI
4
:
oValues of less than 150 mbar or less than 2.18 PSI will not be dis-
played.
oValues of up to 990 mbar will be displayed in mbar and without
decimal.
oValues from 1 bar are displayed in bar with two decimals and from
10 bar with one decimal.
oValues in PSI are displayed with one or two decimals.
4.2 Normal Operating Condition
The pressure leak detector is connected with the interstitial space(s)
through the connection line(s). The excess pressure generated by the
pump is measured and controlled by a pressure sensor.
When the operating pressure is reached (Pump OFF), the pump
shuts off. The pressure drops off slowly due to unavoidable leaks in
the leak detector system. When the ”Pump ON” switching value is
reached, the pump will be turned on and the operating pressure will
be built up again.
Depending on the grade of tightness of the entire unit, the overpres-
sure moves between the switching value Refilling OFF and the
switching value Refilling ON.
4.3 Function in Case of Leaks
If there is a leak in the inner or outer wall, air will leak from the inter-
stitial space. The pressure will fall until the overpressure pump is
turned on to reestablish the operating pressure. If the volume flow
that is flowing out due to the leak is larger than the (limited) feed ca-
pacity of the pump, the pressure in the system will fall and the pump
will work in constant mode.
An enlargement of the leak will lead to further falling of pressure until
the alarm pressure is reached. This triggers the visual, audible and
potential-free alarms.
4
The 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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4.4 Overpressure Valve
The overpressure valve installed in the pressure line protects the in-
terstitial space against impermissibly high pressures (exceeding the
test pressure). Such pressure increases can be caused by outside
factors or a hot filling. In the latter case, it is recommended that the
manufacturer be contacted.
With sufficient pressure resistance of the interstitial space, the over-
pressure valve can be omitted if so agreed between the manufacturer
of the pipe/fitting and SGB.
4.5 Dry filter
A dry filter is needed to dry the incoming ambient air to the point
where condensation does not occur in the interstitial space.
For interstitial spaces underground, the minimum requirement is a
TF 200; larger ones can also be used.
Type
Max. volume (liters) of the interstitial space with
TF 200
TF 400
TF 600
TF 1200
DLR-P 1.1
400
750
1150
2600
DLR-P 1.5
300
650
800
1850
DLR-P 2.0
DLR-P 2.3
250
480
700
1600
DLR-P 2.5
DLR-P 3.0
230
450
600
1400
DLR-P 3.5
150
250
400
950
DLR-P 4.5
4.6 Displays and Controls
4.6.1 Display
Signal
lamps
Operating
Condition
Alarm
condition
Alarm, audible
alarm
acknowledged
Malfunction
OPERA-
TION:
green
ON
ON
ON
ON
ALARM:
red
OFF
ON
BLINKING
ON
LED yellow
Not used or, if dry filter monitoring is connected, yellow and red flash
alternately.
Design and Function

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4.6.2 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.
4.6.3 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 exceed-
ed the "Alarm OFF" pressure.
4.6.4 Function "Tightness inquiry"
Press and hold the "mute" button until the signal lamp is blinking rap-
idly, then release it. The display shows a value for the impermeability
(103, on the version with stainless steel housing). The same value is
indicated by the number of times the “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 operation (i.e.
without external filling, e.g. by an installation 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 depends also on temperature fluctuations and should
thus be considered a reference point.
(103)
Design and Function

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4.6.5 Acknowledgement of the “Dry filter notification” (only if filter check FC provided)
Briefly press the button “Acknowledge dry filter alarm” to shut off the
audible signal. The visual signal (alternate flashing of the red and yel-
low LEDs) continues.
To reset the dry filter alarm completely, press and hold the button un-
til an audible signal sounds.
Design and Function

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5. Installing the System
5.1 Basic Instructions
oPrior to commencing work, the documentation must be read and un-
derstood. In case of ambiguities, please refer to the manufacturer.
oThe safety instructions in this documentation must be adhered to.
oOnly qualified service companies may be used for installation
oComply with relevant regulations for prevention of accidents.
oLead-throughs for pneumatic and electric connection lines,
through which the explosion atmosphere can carry over, must be
sealed gas-tight.
oComply with explosion regulations (if required), e.g. BetrSichV
(and/or directive 1999/92/EC and the laws of the respective
member states resulting therefrom) and/or others.
oIf nitrogen is used to pressurize the interstitial space initially, ap-
propriate safety precautions must be taken (e.g. secure cylinder,
use appropriate pressure reducer, ensure ventilation in areas and
shafts …).
oProvide a test valve at the end facing away from the leak detector
at the end of the pipe(s)/fitting(s).
oBefore entering inspection chambers, the oxygen content must be
tested and the inspection chamber flushed if necessary.
oIf 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.
oImportant 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) NOT in potentially explosive areas.
(3) Plastic housing:
−In a dry room or
−Outdoor in a suitable protective box. This requires an addi-
tional external signal or signal forwarding via voltage-free con-
tacts to a switch board or similar device.
(4) Stainless steel housing: Outdoor or in a building
(5) Dimensions of housings and drilling patterns are illustrated in
Appendix 12.1 to 12.3.
5.3 Dry filter
(1) Near the leak detector, if possible. If a leak detector is installed in
the protective box, the dry filter can be installed in the protection
box or outdoors.
Installation