SGB DLR-GS Documentation

Please read instructions prior to commencing any work As of: 08/2020 Item no.: 604302

- 2 - 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 +49 271 48964-0, email [email protected] 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

- 3 - 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

- 4 - 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

- 5 - 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 

- 6 - 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

- 7 - 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 1 For Germany: e.g. EN 1127 WARNING! Danger from misuse WARNING! Danger in case of incomplete documentation Safety

- 8 - 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

- 9 - 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. 2 Other manufacturers' or countries' regulations may provide different percentages. Safety

- 10 - 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

- 11 - 3.3 Switching Values The following abbreviations are used in the table: pO Maximum 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 3 Switches 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

- 12 - 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 m3 may 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

- 13 - 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

- 14 - 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

- 15 - 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

- 16 - 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). 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

- 17 - 4.5 Displays and Controls 4.5.1 Display Signal lamps Operating Con- dition Refilling acti- vated or re- quired Alarm condition Alarm, 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

- 18 - 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

- 19 - 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

- 20 - 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 mm2 without ferrule - 1.5 mm2 with ferrule and plastic collar Voltage-free contacts and external signal: - 1.5 mm2 without ferrule - 0.75 mm2 with ferrule and plastic collar Mounting

- 21 - 5.8 Electrical Wiring Diagram (1) Power supply: according to label imprint (2) Fixed wiring, i.e. no plug or switch connections (3) Regulations of power supply companies must be adhered to6. (4) Terminal layout: (see also section 5.9.3) 1 / 2 Power connection (100…240 V AC) CAUTION: both terminals exist in duplicate! 3 / 4 not used, internal assignment 5 / 6 External signal (24 V in case of alarm, can be turned off by activating the "Audible alarm signal" button) 11 / 12 Voltage-free contacts (opened in case of alarm or loss of power) 12 / 13 As above, but contacts closed 17 / 18 /19 Voltage-free contacts at “Refilling on”: 17/18 opened 18/19 closed; Voltage-free contacts at “Refilling off” or in currentless condition: 17/18 closed 18/19 opened 21 / 22 Occupied (with internal sensor) 40 / 41 24 V DC as permanent power supply to power other assemblies or, for a device with a supply voltage of 24 V DC, the power supply is connected here 6 For Germany: also VDE regulations Mounting

- 22 - 5.8.1 Connecting the wires (1) Press down the orange point with a screwdriver. This opens the tension spring of the terminal. (2) Insert cable into the open terminal. (3) Hold cable and remove screwdriver. (4) Check cable for a tight fit and install more cables to the terminals using the same process. Mounting

- 23 - 5.9 Installation Examples 5.9.1 Leak detector DLR-GS .. (single, underground pipeline and/or above-ground riser in the building 01 Signal lamp "Alarm", red 51 Test coupling 02 Shut-off cock 57 Test valve 05 Shut-off valve (on pressure reducer) 69 Buzzer 06.2 Coupling, on the leak detector side 71 “Mute” Button 09 Signal lamp "Operation", green 77 Pressure regulating valve 14 Pressure reducer 88 Double-walled pipe 19 Pressure accumulator 99 Control shaft 25 Canister shut-off valve 103 Display 29 Button "Filling" 104 On-site compressed air system 45 Signal lamp "Refilling", yellow (e.g. air/nitrogen) 88 88 57 57 45 71 69 01 09 06.2 14 05 77 25 19 bar 0 16 10 bar 0 100 200 300 02 99 Mounting

- 24 - 5.9.2 Leak detector DLR-GS .. (underground pipeline, series connection) 01 Signal lamp "Alarm", red 51 Test coupling 02 Shut-off cock 57 Test valve 05 Shut-off valve 69 Buzzer 06.2 Coupling, on the leak detector side 71 “Mute” Button 09 Signal lamp "Operation", green 76 Main circuit board 14 Pressure reducer 77 Pressure regulator 19 Pressure cylinder 88 Double-walled pipe 25 Cylinder shut-off valve 99 Inspection chamber 29 Button "Filling" 102 Pressure sensor 30 Housing 103 Display 45 Signal lamp "Refilling", yellow 99 99 57 57 88 88 88 76 30 02 14 05 77 25 19 bar 0 16 10 bar 0 100 200 300 06.2 Mounting

- 25 - 5.9.3 Block diagram 01 Signal lamp "Alarm", red 59.4 Relay "Refilling" 09 Signal lamp "Operation", green 69 Buzzer 24.1 Fuse "Power supply", 2 A 71 “Mute” Button 24.2 Fuse "Solenoid valve", 0.5 A 76 Main board 24.3 Fuse "External signal", 1 A 102 Pressure sensor 29 Button "Filling" 103 Display 44 Solenoid valve 105 Control unit 45 Signal lamp "Refilling", yellow 116 Power supply unit 24 V DC 59.2 Relay "External signal" 140 Contacts for serial data transfer 59.3 Relay "Alarm" 141 Keypad terminal strip Mounting

- 26 - 6. Commissioning (1) Only perform commissioning once the steps in section 5 "Mounting" have been fulfilled. (2) Flush the interstitial space with inert gas if walls of storage me- dium are not impermeable.7 (3) If a leak detector is commissioned on a pipe (fitting) that is al- ready in operation, special protective measures must be taken (e.g. testing that the leak detector and/or the interstitial space is free of gas). Additional measures may be necessary depending on the local conditions and must be assessed by qualified per- sonnel. 6.1 Commissioning the Pressure Gas Bottle (1) Turn pressure regulator all the way back. (2) Insert a suitable manometer (indicating range) into the coupling 51 of the test equipment and insert the test equipment into the coupling (6.2) of the leak detector. (3) Open cylinder shut-off valve (if necessary, test tightness between pressure reducer and bottle) (4) Set pressure on the pressure reducer using the pressure regula- tor on the pressure reducer according to section 3.3 (adjust dur- ing pressure build-up, if necessary). (5) After completion of the functional check: - Close shut-off valve on the pressure reducer. - Close cylinder shut-off valve. - Remove pressure reducer from the bottle (Caution: Gas will escape until the pressure reducer has no pressure). - Install protective cover on bottle. 6.2 Commissioning the Leak Detector (1) Tightness of the interstitial space prior to commissioning is as- sumed (2) Switch on line voltage (3) Ascertain lighting of "Operation" and "Alarm" signal lamps and sounding of the audible alarm. If necessary, turn off audible alarm signal. (4) Pressure build-up the interstitial space: Open the shut-off cock 2.2 at the test equipment to build up the pressure in the leak detector and the interstitial space. With very large interstitial spaces it may be necessary to switch bottles (see section 5.3 in conjunction with sections 5.4 and 6.1) Note: If no pressure build-up is achieved with the pressure gas bottle connected, the leak must be located and corrected (check the settings for the pressure reducer as well, if necessary). 7 For Germany: Additional DIBT requirements must be considered for such double-walled pipes.  Commissioning

- 27 - CAUTION: Display on the leak detector (display) begins with a pressure from 150 mbar. (5) Check all connections for leaks with a foaming agent. (6) Perform a functional check according to section 7.3. 6.3 Changing the Pressure Level (1) Switch positions 1-9 are designed to select the pressure level. (2) The assignment of the switch position to the relevant pressure level is shown in chapter 3.3. (3) If the switch positions 1-9 are changed at the construction site, it must be assured that the operating pressure to be built up does not exceed the test pressure of the interstitial space. Commissioning

- 28 - 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) Even very minor leaks will trigger an alarm. (3) In the event of an alarm, determine the cause and fix it quickly. (4) The leak detector must be disconnected from power for any re- pairs to be performed on the leak detector. (5) A loss of power is indicated by the "Operation" signal lamp going off. Alarm signals are triggered via the voltage-free relay contacts (if used for alarm transmission) if contacts 11 and 12 were used. After the power loss, the green signal lamp lights up again and the voltage-free contacts no longer generate an alarm (unless the power loss has caused the pressure to drop below the alarm pressure). 7.2 Maintenance  Maintenance work and functional checks must be performed by trained personnel only8.  Once a year to ensure functional and operational safety.  Test scope according to section 7.3.  Compliance with the conditions according to sections 5 and 6 must also be tested.  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. 7.3 Functional Check The functional and operational safety tests must be performed:  after each commissioning  in accordance with the time intervals listed in section 7.29  each time a malfunction has been corrected 7.3.1 Test scope (1) Coordinate the work to be performed with those responsible for operation on site, if necessary (2) Observe the safety instructions for working with the product to be conveyed. 8 For Germany: Technical service according to water law with expertise in leak detection systems. For Eu- rope: Authorization by the manufacturer 9 For Germany: In addition, national laws apply (e.g. AwSV) Functional Check and Maintenance

- 29 - (3) Check the test valve at the end of the interstitial space pointing away from the leak detector for tightness and contamination, and clean it, if necessary (4) Checking the free passage of air in the interstitial space (section 7.3.2) (5) Testing the switching values (section 7.3.3) (6) Tightness test following commissioning or correction of malfunc- tions (section 7.3.4) (7) Creating the operating condition (section 7.3.5) (8) A qualified person must complete a test report, confirming func- tional and operational safety. 7.3.2 Checking the free passage of air in the interstitial space If several interstitial spaces are connected in parallel, each one of them must be checked for passage. (1) Insert measuring gauge into the test coupling 6.2. The current pressure in the interstitial space will be displayed. (2) Open the test valve for the first connected interstitial space. (3) Check whether the measuring gauge registers a pressure drop. (4) Close the test valve. (5) Repeat process from paragraph (2) to (4) for each additional test valve of the interstitial space(s) connected to this leak detector. (6) The pressure drop generated by the test can be compensated as follows: a) Remove the measuring gauge from the coupling and insert it into the test coupling 51 of the test equipment. b) Insert the test equipment into coupling 6.2. c) Connect the pressure cylinder to the test equipment acc. To chapter 5.3 (5.4 and 6.1) d) Open the shut-off cock 2.2. e) Pressure build-up until pressure setpoint; during filling, moni- tor the pressure on the pressure reducer (test pressure must not be exceeded) and re-adjust if necessary f) Once the filling process has been completed, close the shut- off valve on the pressure reducer, and disconnect the meas- uring gauge and pressure cylinder. 7.3.3 Testing the switching values (1) If several interstitial spaces are connected through a distribution system, close all shut-off cocks on the distributor. (2) Insert the test equipment into the coupling 6.2 (3) Insert the manometer into the test coupling 51 of the test equip- ment. Functional Check and Maintenance

- 30 - (4) Connect the pressure cylinder to the test equipment acc. To chapter 5.3 (5.4 and 6.1). (5) Bleed the shut-off cock 2.1 to determine the switching values “Refilling required” (the yellow signal lamp, if available, lights up) and for “Alarm ON”. Record the values. (6) Close the shut-off cock. (7) (Slowly) open the shut-off cock 2.2. During the pressure build-up, check the switching values for “Alarm OFF” and “Refilling (here: Filling) OFF” (if available). Record the values. (8) Close the shut-off cocks. Remove the pressure cylinder properly and decouple the test equipment. (9) The test is considered passed if the values specified in section 3.3 have been satisfied. (10) Open all shut-off cocks in the connection line(s). 7.3.4 Tightness test following commissioning or correction of malfunctions10 (1) Insert measuring gauge into the coupling 6.2. The measuring gauge will display the current pressure. (2) The tightness test is approved for one year of trouble-free opera- tion if the following conditions have been met: Determine the difference between the measured values for “Re- filling (Filling) OFF” and “Alarm ON” and convert into mbar (x 1000). Divide the calculated value by 8760. This results in a maximum tolerated pressure drop (per hour) to prevent triggering an alarm before one year has passed. If the determined value cannot be measured, multiplication of the pressure drop will re- sult in the same multiplication of the test time. Example: Difference between the above-named switching values: 1.75 bar (value measured on site) 1.75 x 1000 = 1750 1750 / 8760 = 0.2 mbar/h (admissible pressure drop) The measuring gauge available on site “only” shows a value of 5 mbar. This means the readability is 25 times (5 / 0.2). This ex- tends the test time to 25 hours. (3) Disconnect the measuring gauge after the tightness test has been completed. 7.3.5 Creating the operating condition (1) Seal the housing and the test valve(s) at the end of the interstitial space pointing away from the leak detector. (2) If shut-off cocks have been installed in the connection lines, they must be sealed in an opened position (if connected to an intersti- tial space). 10 This section assumes that the operating pressure has been built up in the interstitial space and the pres- sure has been compensated. Functional Check and Maintenance

- 31 - 8. Alarm (Malfunction) 8.1 Alarm (1) The red signal lamp lights up (yellow also lights up if existing), the audible signal sounds. (2) Turn the audible signal off. 8.2 Malfunction (1) In case of a malfunction, only the red signal lamp will light up (yellow is off), and at the same time the audible signal cannot be acknowledged. 8.3 How to Behave (1) Inform the installation company immediately and state the display from the preceding paragraph. (2) Determine the cause for the alarm, fix it, and then perform a func- tional check for the leak detection system according to section 7.3. Alarm

- 32 - 9. Spare Parts See also online shop shop.sgb.de Switchboard (for plastic housing): 331670 Switchboard VD SMD L with LED and transformer 630 mA (please indicate pressure level) 331725 Display board for electronic leak indicator, VL, VLR, DL, DLG, DLR-G, DLR-P Manifold: 412690 Manifold DLR-GS with sensor 20 bar and flange plate in- cluding test coupling (please indicate screw connection) 412691 Manifold DLR-GS with sensor 40 bar and flange plate in- cluding test coupling (please indicate screw connection) Pressure sensors: 344520 Sensor 20 bar for DLR-GS 344540 Sensor 40 bar for DLR-GS Housing: 220220 Housing lower part, "ABS" RAL 7033 (dark gray) 220210 Upper housing part, "ABS", RAL 7171 (light gray) 220214 Upper housing part, light gray, only mounted display Spare Parts

- 33 - 10. Accessories For accessories please refer to our online shop shop.sgb.de, e.g. - Installation kits - Electrical isolators - Manifolds - Pressure reducers - Remote data transmission (LOD) - P version, housing with IP 54 Accessories

- 34 - 11. Disassembly and Disposal 11.1 Disassembly Prior to and during works, make sure the unit is free of gas and the breathing air contains sufficient oxygen levels. Seal any openings gas-tight through which an explosion atmosphere can carry over. Avoid using spark-producing tools (saws, parting grinders, etc.) for disassembly whenever possible. Should this be unavoidable, how- ever, comply with EN 1127 or the area must be free of explosive at- mosphere. Avoid the build-up of electrostatic charges (e.g. through friction). 11.2 Disposal Properly dispose of contaminated components (possibly through out- gassing). Properly dispose of electronic components. Disassembly and Disposal

- 35 - 12. Appendix 12.1 Dimensions and Drilling Pattern, Plastic Housing D = 110 170 230 30 100 210 265 ~ 250 Space needed to remove the housing lid Space needed to open the housing lid Appendix

- 36 - 12.2 Dimensions and Drilling Pattern, Stainless Steel Housing for Installation Outdoors (IP 54) D = 80 Ø8,5 220 243 268 250 280 320 Appendix

- 37 - 12.3 Declaration of Conformity We, SGB GmbH Hofstraße 10 57076 Siegen, Germany, hereby declare in sole responsibility that the leak detectors DLR-GS are in conformity with the essential requirements of the EU directives listed below. In case the device is modified or used 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 61 000-6-3: 2011 EN 61 000-6-2: 2006 EN 61 000-3-2: 2015 EN 61 000-3-3: 2014 2014/35/EU Low Voltage Directive EN 60 335-1: 2012 EN 61 010-1: 2010 EN 60 730-1: 2011 2014/34/EU Equipment for Explo- sive Atmospheres The pneumatic components of the leak detector may be connected to spaces (interstitial spaces of containers/pipes/fittings) that require category 3 devices. The following documents have been consulted: EN 1127-1: 2011 The ignition hazard assessment did not result in any additional haz- ards. Conformity is declared by: ppa. Martin Hücking (Technical Director) As of: 02/2019 Appendix

- 38 - 12.4 Declaration of Performance Number: 008 EU-BauPVO 2015 1. Unique identification code of the product type: Pressure leak detector type DLR-GS 2. Usage purpose: Class I pressure leak detector for monitoring double-walled pipes 3. Manufacturer: SGB GmbH, Hofstr. 10, 57076 Siegen, Germany Phone: +49 271 48964-0, E-Mail: [email protected] 4. Authorized representative: n/a 5. System of assessment and verification of constancy of performance: System 3 6. In the case of the declaration of performance concerning a construction product that is cov- ered by a harmonized 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 Harmonized norm 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 depending on housing type 0°C .. +40°C -40°C .. +60°C 8. Signed for and on behalf of the manufacturer by: Dipl.-Ing. M. Hücking, Technical Director Siegen, 31-10-2015 12.5 Manufacturer’s declaration of compliance Compliance of the leak detector with the “Muster-Verwaltungs- vorschrift Technische Baubestimmungen“ (sample administrative reg- ulation technical building regulations) is hereby declared. Appendix

- 40 - Text Legal notice SGB GmbH Hofstr. 10 57076 Siegen Germany T +49 271 48964-0 Photos and dimension are not binding E [email protected] for the extent of delivery. Subject to W www.sgb.de changes. © SGB GmbH, 08/2020 Text