leak detection_dc pipe

8/18/2019 Leak Detection_DC Pipe

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© CWA SYSTEM ABP.O. Box 4007, S-131 04 NACKA, SWEDEN

1

LEAK DETECTION

INSTALLATIONANDOPERATION MANUAL

PAGE 3-26 CWA 9000 START-UP AND OPERATION

28 TYPICAL INSTALLATION CWA 900

29 BLOCK SCHEMATICS

30 COMPONENT PLACEMENT

31 DIMENSIONS

32 TERMINALS

34 HEATER

35-40 MATCHING BOX CWA 9092

41-49 SENSOR WIRES

50-55 PLANNING OF ALARM SYSTEM

56-63 INSTALLATION OF SENSOR WIRES

65-65 WORK SHEET

66-69 ELECTRICAL TES T


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Operation instructionsCWA 9000

Also refer to project manual for specific data.

Selfcheck................................................. LE. 9: 13

Sensitivity setting .................................... LE. 9: 14

Propagation speed ................................... LE. 9: 15

Cable end ................................................ LE. 9: 16

Measuring line ......................................... LE. 9: 17

Offset zero .............................................. LE. 9: 18

Offset zero yes ........................................ LE. 9: 19

Adjust propagation speed ....................... LE. 9: 20

User numbers and access code ................ LE. 9: 24

Set password ........................................... LE. 9: 25

Set clock ................................................. LE. 9: 26

Alarm test ................................................ LE. 9: 27

Alarm memory ........................................ LE. 9: 28

Clearing alarmtable ................................. LE. 9: 29

Disable channel ....................................... LE. 9: 31

Enable channel ........................................ LE. 9: 32

Error codes ............................................. LE. 9: 33

Start up

Monitoring


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NOTE:before THE START-UP, it is necessary to have checked thewhole pipesection according to the installation/testinginstructions.It is also advised that all reference-points have been establishedand the appropriate forms have been filled-in.

Make sure that all as-built-drawings are properly up-dated withallCompensators, Tees and Elbow marked, all distance measure-ments are noted on the same. All drawings should be availableduring start-up.

It is also advised that the TDR is available if there should occur

any problems. The LCD screen on the LD Unit will instruct youon the proceedings step by step and it will be simple to followthe instructions.

To start the unit:Connect the wires/cables to monitor.Connect the mains power according to appropriate “TerminalBlock Configuration” paper.

1. Unit equipped with BBUThe fuses on the terminal block are used as switches for:Fuse 3 Mains Power.Fuse 5 12 VDC to Leak Detector 1.Fuse 7 12 VDC to Leak Detector 2.Fuse 28 Heating Power Leak Detector 1.Fuse 29 Heating Power Leak Detector 2.Fuse 32 For Battery.

2. Unit without BBU

Fuse 12 Mains Power.Fuse 13 Heater if Heater is installed.

When the unit was installed and connected the fuses were re-leased.Press down all fuses.The unit will start up and the display’s backlight is on.

Display reads:VER. 4.20

COMADS. xxANY KEY TO PROCEED


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eo553

Leak detector frontplate

Used configuration in the examples.


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The unit has four different sensitivity levels. The sensitivity levelthat shall be used depends on what kind of liquids that are to bemonitored and the type of sensor cable/wire that is being used.

Sensitivity is most sensitive and least sensitive.

[For District Heating sensitivity is recommended.]

For other applications, refer to project manual.

The unit will ask for the sensitivity setting for each channelinstalled individually.

Sensitivity setting

Press the number that corre-sponds to the sensitivity thatshall be used for channel 1.

If not OK, press button 1 - 3to make correct setting.

[Press M/R only when setting iscorrect.]

The sensitivity settings must bemade for all the installedchannels individually.You will be prompted.

SET SENSITIVITY CH.1, , ,

Example: PRESS: 4

CHANNEL 1SENSITIVITY

M/R TO ACCEPT


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The unit has to know the propagation speed for each installedchannel and it’s cable.For District Heating with direct applied foam, propagation speed isusually 91%.

Propagation speed

PRESS: 9 1 0

SET PROPAGATIONSPEED FOR CHANNEL 1ENTER 3 DIGITSREL. SPEED =

This is where you tell the unit thebasic electrical value of thecable to be monitored.

See cable specifications.

The value shall be set with 3digits and is the relative pulsepropagation speed in % of thespeed of light.

Example: 91%

After having entered the propaga-tion speed, the unit automaticallyINITIALIZES itself, stores thegiven values in the memory andmakes a new self check.This sequence is ended when unitpresents: CABLE END FOUNDAT xxxx

This procedure may take sometime depending on cable length.

SET PROPAGATIONSPEED FOR CHANNEL 1ENTER 3 DIGITSREL. SPEED = 0,910

INITIALIZING ch:1

This value is a goodstart for most pre-insulated pipes. Werecommend that youalso use the

function:"Adjustpropagationspeed"

to get accuratereadings in case of aleak.


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The unit presents the distance tothe cable end. This value is notexact, but should correspond tothe physical length within

- 0% / + 10%.See fig.Fill out the given value in the“Start-Up Form”.

Cable end CHANNEL 1:SET UP TO MONITOR

860 METERS

TO PROCEED

Figure: Cable End presention.

NOTE:Later on in the start-up procedure, it is possible to adjust thepropagation speed to get the exact cable length corresponding tothe physical length of the pipe system.

Differences greater than + 10% at this stage are unusual. If the valueis drastically shorter than expected, a break is present.

Check with TDR.

If the value is much longer, you may not have an open end of thecable.

Check with TDR.

The echo from the open end can also be too small, due to impedancemismatches on the cable.

Check with TDR.

Example:Physical length = 860 metersGiven value = 530 meters

Check with TDR and repair.

After having the right distance displayed:

EO557

PRESS: F


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Here, the cable is also being checked for acceptance of use. Youwill be notified if so.This is a slow procedure; it can take about 1 min./ 100 meters of wire.

Measuring Line

Wait while the unit measures thecable and stores the digitizedvalues for every timeslot in thememory.

MEASURING LINE 1

COMPUTING LIMITS

CH. 1OFFSET ZERO ?

=YES =NO

Wait while the unit is computingUPPER and LOWER ALARMLIMITS, and storing thosevalues in the RAM memory.This is also a slow procedure, itcan take about 2 min./ 100meters.

After completion of the “Meas-uring Line” sequence the displaywill read.

EO558

Figure: Computing limits.


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The OFFSET ZERO function is used when you have the Leak Detector unit installed far away from the startpoint of the sensorwire and a Jumper Cable RG 58 C/U is used between the Leak Detector Unit and the matchingbox CWA 9091. The Jumper

Cable can be max. 100 m. long. The OFFSET ZERO functionenables the Jumper Cable to be “integrated” into the unit so thatthe measuring starts at the connection point at the pipe.

NOTE:A Break or a Short along the Jumper Cable will be displayed as anegative value on the LCD display.

Example: [ BREAK AT -47 m ] means that the break is at 47 mfrom the desired ZERO POINT towards the Leak Detector.

Offset zero

Figure: OFFSET ZERO Not in function

EO559

The display gives 2 choices:

ALT. A:Let the unit measure the entirecable from the connectors inbottom of the unit.

If the unit is equipped with morethan one channel the next stepwill be sensitively setting fornext channel. i.e Ch. 2 ,3 ,4

CH. 1OFFSET ZERO ?

=YES =NO

PRESS: R

PRESS: F

See page LE. 9: 14.

ALT. B:B: YES: Go to next page.Let the unit measure from thepipe-end.


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Alternative B:If you have an installation where different cabletypes with differ-ent propagation speeds are used, (usually coax RG 58 as a

jumper cable ) between the unit and the detector cable, you may

choose to “integrate” the jumper cable into the unit.This is advantageous because the two cables have differentelectrical characteristics and propagation speeds and thereforewill give erroneous distance values in case of a Leak/Break alarm.

Offset zero yes

DISCONNECT CABLE 1AT THE DESIRED ZEROPOINT THEN PRESS

ANY KEY TO PROCEED

ZERO POINT LOCATED67 meters

FROM THIS UNITANY KEY TO PROCEED

PRESS: any

RECONNECT CABLEAT ZERO POINT THENANY KEY TOCONTINUE

PRESS: any

Figure: OFFSET ZERO in function

EO5510

Reconnect the cable at theZeropoint.

If the unit is equipped with morethan one channel the next stepwill be sensitively setting for nextchannel.

Go to page LE. 9: 14 and pro-ceed from there.

The display gives the distance tothe Zeropoint.

Fill out the given value in the“Start-Up Form”.

Disconnect the cable at thedesired Zeropoint (usually thematchingbox).Disconnect AFTERmatchingbox, not the BNCconnector.


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Offset Zero and CableEnd when MB CWA9092 is installed

To make the start up procedure easier the Matching Box CWA9092 is equipped with a 3-way switch. The 3 positions are used inthe following way:Never operate this switch except during "Start-Up"procedure.

1. NormalThe normal position. Check that the switch is set in this positionbefore the start up procedure is started.The switch shall also be in this position in monitoring mode.

Cable End

Offset Zero

Normal

Cable End

Offset Zero

Normal

Cable End

Offset Zero

Normal

3. Cable EndThe switch makes a short at the end of the leak detection loop. Usedwhen the Propagation speed shall be adjusted.When the unit prompts you to "short the far end of the cable(s)tobe adjusted" , set the switch in this position.When the unit prompts you to "remove the shorts at cableends" , set the switch back to Normal position

2. Offset ZeroThe switch makes a break at the beginning of the leak detectionloop. Used when the Offset Zero point shall be detected.When the unit prompts you to "disconnect the cable at desiredzero point" , set the switch in this position.When the unit prompts you to "reconnect the cable" , set theswitch back to Normal position.

CWA 9000

CWA 9000

CWA 9000

Closed

Open

Open

Closed

Closed

Open

Pipe with sensorwires



Do NOT forget toset switch in"NORMAL"

position.


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Adjust propagationspeed

When all the installed channels are initialized, it is possible toadjust the propagation speed until the reading on the displaycorresponds to known physical length of the cable/sensorwire.

You have two choices:

ALT. A:If no adjustment is necessarypress and the unit willproceed into MONITORINGMODE, see page LE. 9: 23.

ADJUST PROPAGATIONSPEED FOR CABLES=YES =NO

PRESS: R

If no adjustment is desired

PRESS: F

If adjustment is desired

ALT. B:If, for example, the propagationspeed for channel 1 shall beadjusted:Make a temporary short at thefar end(s) of the cable(s).NOTE:It is recommended to make ashort at all wires/cables at thesame time.

Press the number that corre-sponds to the channel that shallbe adjusted.

SHORT THE FAR ENDO FTHE CABLE(S) TO BEADJUSTEDANY KEY TO PROCEED

PRESS: any

CHANGE SPEED FORCHANNEL NO.

TO PROCEED

EO5511

Figure: Adjust Propagation speed function.


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CHANGE SPEED FOR

CHANNEL NO.

TO PROCEED


First, try with the same propaga-tion speed as initiated ( 910 ).

The unit presents the new dis-tance to the shorted end.

NOTE !:If the OFFSET ZERO functionis used, the distance from theZERO POINT will bedisplayedwhen changing thepropagation speed.

The displayed length is 13 mlonger than the correct length inour example.

Enter the number of next

channel (if applicable).Enter to proceed to nextfunction.

PRESS: 1

SET PROPAGATIONSPEED FOR CHANNEL 1ENTER 3 DIGITSREL. SPEED = 0.

Example: 9 1 0

SET PROPAGATIONSPEED FOR CHANNEL 1ENTER 3 DIGITSREL. SPEED = 0.910

MEASURING LINE

CHANNEL 1:CABLE END FOUND AT

733 metersANY KEY TO PROCEED

PRESS: any


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The read-out from the display was a little to long and therefore itis necessary to make a new adjustment.For the calculation of the right propagation speed the followingrule can be used.

Displayed length < The correct length : Use a higher propagationspeed.Displayed length > The correct length : Use a lower propaga-tionspeed.In our example we shall accordingly use a slower propagationspeed.


SET PROPAGATIONSPEED FOR CHANNEL 1ENTER 3 DIGITSREL. SPEED = 0.

Since the new reading was notcorrect, try with new values untila correct value is displayed.

When the displayed length is

correct for the first channel thenext channel can be adjusted bypressing the button correspond-ing to the channel number.

When all channels are adjusted.

The unit will remind you toremove the shorts.

PRESS: 1

PRESS: any any any5-9 0-9 0-9

CHANGE SPEED FORCHANNEL NO.

TO PROCEED

TIME: 25 FEB 13:51MONITORING CHAN. 1

REMOVE SHORTS ATCABLE ENDS

ANY KEY TO PROCEED

PRESS: F

Background light off

Initializing procedure is now completed. The unit monitors

channel 1, this is the normal working mode. When monitoringmore than one channel, the unit changes channel numberaccording to the channel that is being monitored.


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Level USERNUMBER ACCESS TO

:DISABLE CHANNEL:ENABLE CHANNEL

:SET CLOCK:EXIT,:MORE

:SET PASSWORD:CLEAR ALARMTABLE

:SET COLDSTART:EXIT

:DISABLE CHANNEL:ENABLE CHANNEL:SET CLOCK:EXIT

00

1 01

02

030405

2 06070809

10

3

50

Open Read Memory F

Reset F

User numbers andsecurity levels

USER NUMBER and ACCESS CODE table.

The security codes are implemented to prevent un-authorizedtampering with the pipe alarm system, thereby securing that allmessages and alarms are being handled by authorized persons.


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Now it is advisable to set desired individual USER NUMBERSand ACCESS CODES (pass words). This can ONLY be done bysome one with user no. 00, 01, 02.The access codes can be programmed individually and we sug-

gest that you use a code which is easily remembered.

User numbers andaccess code

PRESS: 1

:SET PASSWORD:CLEAR ALARMTABLE:SET COLDSTART:EXIT

MENU 2

PRESS: F

:DISABLE CHANNEL

:ENABLE CHANNEL:SET CLOCK:EXIT ,:MORE

MENU 1

ENTER USER NO. 00ENTER ACCESS CODE

*****

ENTER ACCESS CODE: 1 0 0 0 0

0 0

ENTER USER NUMBER:


Background light on

PRESS: F

TIME: 25 FEB 13:51MONITORING CHAN. 1

Normal display.

The unit is delivered with DE-FAULT ACCESS CODE forUSER NUMBER 00.The ACCESS CODE is 10000.

You can change also that codeto anything you like if the valueis less than 64000.

If you enter the wrong ACCESSCODE for a USER NUMBER ,you will be notified with themessage: [NOT VALID !].You must start over again, bypressing the key.

Default.

Choose function.

Choose function 1.


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The security levels are divided into three groups and one freewhich is open for all persons. The USER NO. gives theaccessible security levels. See page LE. 9: 23.

USER NUMBER: 00, 01, 02 have access to all functions andcommands including setting USER NUMBERs and ACCESSCODEs.

USER NUMBER: 03, 04, 05, 06, 07, 08, 09 have a limitedaccess but can handle the following:DISABLE/ENABLE CHANNEL, SET CLOCK and RESETALARM.

USER NUMBER: 10 - 49 can only RESET ALARM.

Set password

ENTER USER NO. 00

ENTER: 0 0

ENTER USER NO. 00ENTER CODE, 5 DIGITS

MAX NUMBER=64000

ENTER:

1 2 3 4 5

TIME: 25 FEB 13:51

MONITORING CHAN. 1


ENTER USER NO.You are prompted to enter yourUSER NUMBER.As an example 00.

The highest ACCESS CODE is64000.

Do not exceed that value.

As an example.

Proceed with the following user

numbers in each security levelas described above.


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The unit is equipped with a clock and full calendar.Setting the clock to actual values is described in this part.

Set clock

Enter USER NUMBEREnter ACCESS CODE

The display now presents thedate, month and time ( 24 hour ).The date may be right but thetime has to be set unless correct.

Use the arrow keys to changemonth.

= UP = DOWNPress for next window.

Use the arrow keys to changeday.

Use the arrow keys to changehour.

Use the arrow keys to changeminutes.Press to exit.

TIME: 25 FEB 13:41

MONITORING CHAN. 1


Set Minutes

=+ =-,=EXIT

Set hour 14

=+ =-,=EXIT

Set day 26

=+ =-,=EXIT

Set month Feb

=+ =-,=EXIT

Time: 26 Feb 14:34

=SET TIMEAll other exit

PRESS: 3

:DISABLE CHANNEL:ENABLE CHANNEL:SET CLOCK:EXIT ,:MORE

Background light on

PRESS: F

TIME: 25 FEB 14:51

MONITORING CHAN. 1

Choose function .


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You are recommended to make at least one Alarm Test to verifythat everything is OK with the installation and entered values.

Alarm test

TIME: 25 FEB 14:46MONITORING CHAN. 1FOR 134 meters

Background light is off

PRESS: R

TIME: 25 FEB 13:41

MONITORING CHAN. 1

Simulate a fault by shorting the

cable somewhere along the linewhere the sensorwire/cable iseasily accessible (Referencepoint).You can use anything that fits.

1 0 0 0 0

PRESS:

PRESS: 0 0

ENTER USER NO. 00ENTER ACCESS CODE *****

PRESS: R

ALARM INHIBITwill silence the buzzer andrelease relay. will look thedisplay and keep the backlighton.

RESETwill Reset the alarm.

The unit will now ask for youruser number.Enter your USER NUMBERand ACCESS CODE.

ENTER USER NUMBERor any you have previouslyentered.

PRESS: A/I

ALARM CHANNEL :1TIME: 25 FEB 14:06LEAK 137 metersPRESS TO RESET

Background light is flashing

ENTER ACCESS CODEor what you have previouslyentered.

For Reset.

The alarm is Reseted and theunit is back into normalworking mode except for thatit only monitors the cable upto the fault minus 3 meters.

The alarm is still stored in thememory and can be recalledwhenever needed.

After a while, depending on thelength of the wire and distance toalarm and number of channels,the alarm will sound and thedisplay shows for example :


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All alarms are stored in the battery backed memory and can berecalled whenever needed.

The ALARM TABLE can also be erased and we advise you to

do so before turning over the installation to the owner, therebyensuring that all future alarms are ALARMS trigged afterinstallation.

Alarm memory

EXAMINE WHICHCHANNEL

Background light is on

PRESS: 1

CH.1 ENTRY NO. 1TIME: 25 FEB 14:36LEAK 137 metersPRESS MR TO EXIT

PRESS: M/R

PRESS: M/R

CH.1 LAST ENTRYTIME: xx FEB 14:36LEAK xxx metersPRESS MR TO EXIT

Press the number that corre-sponds to the channel numberto be examined.

Or any other installed (2,3,4)you want to examine.

If there are more alarms , theycan be displayed by using thearrow keys. It is possible to“scroll” up and down in thetable.

To exit the alarm table mode.

Indicates that there are nomore messages in the table inquestion.


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Clearing alarmtable

TIME: 25 FEB 14:46MONITORING CHAN. 1FOR 134 meters


PRESS: F

ENTER USER NO.


PRESS: 0 0


1 2 3 4 5

PRESS:


*****

If the unit shall be able to monitor the entire length of the cable,it is necessary to clear the alarmtable after the fault is repaired.

Enter your user number.

To clear an alarmtable.

Enter your access code.

If the entered USER NUMBERand ACCESS code correspondswith the stored codes, it givesaccess to MENU 1.


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Clearing alarmtable

:DISABLE CHANNEL:ENABLE CHANNEL:SET CLOCK:EXIT ,:MORE

:SET PASSWORD:CLEAR ALARMTABLE:SET COLDSTART:EXIT

PRESS: F

PRESS: 2

Choose function .For menu 2.

Choose function .

PRESS TO CLEARTABLE NO. 1KEEP PRESSED TO 1000

999

PRESS: R

Menu 1

Menu 2

For [ CLEAR ALARMTABLE ]function.

For your own protection, thememory can not be cleared just bypressing one key.

As the display says, hold the pressed while a counter goes from0, counting up to 999.

If you release the button before

1000 is reached, you have to startover again.

The alarmtable is now empty and the unit is monitoring the entirelength.

If the fault that caused the alarm is not repaired, a new alarm willbe trigged.


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Disable channel

:DISABLE CHANNEL:ENABLE CHANNEL:SET CLOCK:EXIT,:MORE


NOT MONITORING

ALL CHANNELS DISA-BLE

Time: 26 Feb 14:27MONITORING CHAN. 2

PRESS: F

PRESS: 1

MONITORING CHAN-NELS1, 2

CHANNEL TO DISABLE

PRESS: 1

MONITORING CHAN-NELS2,

CHANNEL TO DISABLE


Choose function .

You can disable any channel thatis installed.

If you intend to disable channel1.

The display tells whichchannel(s) that is beingmonitored.If you disable all installed chan-nels the display warns you bytelling:

THE UNIT IS NOT MONI-TORING.

It is possible to disable one or more channels.This function shall/can be used while repairing a fault.


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Enable channel

Time: 26 Feb 14:28

MONITORING CHAN. 1


MONITORING CHAN-NELS1, 2

CHANNEL TO ENABLE

PRESS: 1

Time: 26 Feb 14:27MONITORING CHAN. 2

PRESS: F

:DISABLE CHANNEL:ENABLE CHANNEL:SET CLOCK:EXIT,:MORE


PRESS: 2

MONITORINGCHANNELS2

CHANNEL TO DISABLE

After having disabled any channel for some reason, you have toenable the channel again.

This shall also be done after you have received an ERROR

message on the display and found out what caused the error andrepaired the same.


Choose function .

You can enable any channelthat is installed.

If you intend to enable channel1.

The display tells whichchannels that is beingmonitored.


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Error codes

The procedure to enable the channel with an ERROR is:

1. Clear the Alarmtable for the channel in question (see page LE. 9: 30).

2. Enable the channel in question (see page LE. 9: 32).

* ERROR * ERROR *CHANNEL NO. 1IS FAULTYAND DISABLED

Background light is flashing.

An error message will be displayed if there is any fault on theanalog board(s) in the unit, or if you have a fault on the first 10meters of the detector cable or Jumper cable.

NOTE: An ERROR message automatically DISABLES thechannel in question.


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Application: Heating element for use in Leak Detec-tors whenever the environmental temperature isexpected to be lower than 0 °C.Space is reserved on mounting plate. Thermostat is included.

CWA Heater Unit

Specification: CWA Heater UnitMechanical:Dimensions: 115 x 70 x 50 mmWeight: 300 gramsElectrical:Power: 230 VACPower consumption: 33 Watt

Connection: Connect to mains terminal block and

thermostat.


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MATCHINGBOX

1. Matchingbox CWA 9091

2. Block schematics

3. Mechanical

In any piping system, above or below ground, there is always arisk of for earth currents and transients. Those “signals” candamage electronic parts and systems.CWA 9091 MATCHINGBOX is designed to drain such signalsto ground and also to match the signals from the Leak Detectorto smoothly pass over to the sensor wires or cables. It is a smallbut important unit.


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Application: District HeatingThe Matchingbox is connected between the alarmunit and thealarmwire (sensorwire) at the startpoint of every pipesection.The purpose is to “match the transmitted pulse” from the alarmunit to the impedance of the alarmwire as well as galvanicallyisolate the alarmunit from the wire and pipe.

CWA 9092

Specification: CWA 9092Power: Not applicableSize: 180 x 80 x 56 mmWeight: 750 gramsTemperature range: -10 - +70 C.

Input: BNC connector 50 OhmOutput: Connection cable 1,25m, mountedProtection Class: IP 65


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NOTE: See also PDF file CWA 9092, MatchingBox for details


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This side is by intention left blank for your notes and future use.

Offset Zero and CableEnd when MB CWA9092 is installed

To make the start up procedure easier the Matching Box CWA9092 is equipped with a 3-way switch. The 3 positions are used inthe following way:Never operate this switch except during "Start-Up"procedure.

1. NormalThe normal position. Check that the switch is set in this positionbefore the start up procedure is started.The switch shall also be in this position in monitoring mode.

Cable End

Offset Zero

Normal

Cable End

Offset Zero

Normal

Cable End

Offset Zero

Normal

3. Cable EndThe switch makes a short at the end of the leak detection loop. Usedwhen the Propagation speed shall be adjusted.When the unit prompts you to "short the far end of the cable(s)tobe adjusted" , set the switch in this position.When the unit prompts you to "remove the shorts at cableends" , set the switch back to Normal position

2. Offset ZeroThe switch makes a break at the beginning of the leak detectionloop. Used when the Offset Zero point shall be detected.When the unit prompts you to "disconnect the cable at desiredzero point" , set the switch in this position.When the unit prompts you to "reconnect the cable" , set theswitch back to Normal position.

CWA 9000

CWA 9000

CWA 9000

Closed

Open

Open

Closed

Closed

Open





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SENSOR WIRES INPIPES,JOINTS AND FITTINGS

1. CWA Crimp ConnectorCWA Sensor Wire

CWA Joint Activator

2. Design Guide

3. Planning Guide

4. Installation

5. TestingTest Format

The Leak Detection / Location system consists of TWOimportant parts: The SENSOR WIRE and LEAK DETECTORS.The installation and connection of the sensorwires is veryimportant as they are placed underground inside the insulation,mistakes here can be difficult to repair.The instructions and methods in this part is the result of over 20years of experience and have proven to be reliable.


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Application: For connecting Alarm wiresThe CWA Crimp connector is used for connecting alarmwires bycrimping and soldering.Use of CWA Crimp Plier is mandatory.

CWA CrimpConnector

CWA Sensor Wire

Specification: Crimp ConnectorMechanical: L = 8.2 mmInner dia. 3.2 mmOuter dia. 5.7 mm

Delivered in boxes of 100 pieces.

The sensor wire is used in pre-insulated District Heating pipeswhere it is placed in the insulation foam 15 - 20 mm from thecarrier pipe.

Specification:Uninsulated, fully annealed, solid, pure copper wire.1,5 or 1,7 sq. (1,3 - 1,5 mm dia)Connected by crimping and soldering with CWA CrimpConnector.Delivered from CWA or Local.


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Application: For District Heating jointsIs used in the joints to secure the alarm wire at a certain distancefrom the pipe during foaming of the joint.Made of specially treated felt which is heat resistant.

CWA Joint Activator

Specification: CWA Joint ActivatorMechanical: L = 400 mm

W = 100 mmT = 10 mm

Delivered in boxes of 100 pieces.


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Design guide forpipes and fittingswith CWA alarmsystems

ProductionProduction of pipes and fittings with CWA Sensor Wires is quitesimple and economical. Moreover, very few additional equip-ment is necessary to run a smooth and effective production line.

The layout and design can be fully implemented into any existingproduction-line.

Investments are minimized and require no extra tooling exceptfor the wire supports that should be integrated in the presentcentering pieces that are being used in current production.

The use of specified copper wires, which are available asstandard from local suppliers, reduces the cost/pipe to minimum.

All pipes and fittings are fully symmetrical and can be tailored toany measurement or produced as standard parts that are inter-changeable with each other and within wide ranges of pipe-diameters.Pipesizes over 250 mm are recommended to have 4 sensor wiresfor maximum safety and ease of handling at site.

It is recommended that one wire is tinned and the other is blank copper just for identification purpose. That will also minimize the

risk for crossed wires in field-joints.

The sensor wire is used in pre-insulated District Heating pipeswhere it is placed in the insulation foam 15-20 mm from thecarrier pipe.

Specification:Uninssulated, fully annealed, solid, pure copper wire.1,5 or 1,7 sq (1,3-1,5 mm dia.).Connected by crimping and soldering with CWA Crimp Connec-tor.Delivered from CWA or Local.

CWA Sensor Wire


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The manufacturing of straight pipes is described under part“Manufacturing”.Distance between sensorwire and pipe is min. 15 mm / max. 20mm.

Elbows are manufactured in 2 ways;The regular elbow is intended to be installed horizontally.The other type is most commonly used to enter buildings or topass (above or under) obstacle.

Straight Pipes

Elbows


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T-pieces T-pieces always carry 3 wires. One wire goes straight throughand the other wires form the “T”.T-pieces can be placed in left or right hand position withoutaffecting the function or principle in lay-out.

NOTE:

Important

The compensator is manufactured with more wire than the actualmechanical length.That length is important and is noted on the individual compen-sator.Length differs also depending on diameter.Wire can be laid spirally wound or in a loop. Both giving the

possibility of movements.

As the compensator carries more wire than it’s mechanicallength, the position of the compensator and the length of it’s“built-in” wire MUST BE NOTED on the as-built-drawing.Otherwise, problems will occure in faultlocation.

Compensators


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The CWA 9000 System is based on very logical and easy tounderstand lay-outs of the sensor wires. It makes it possible tomonitor any pipe-layout in any environment.

The Leak Detector can be placed and replaced anywhere alongthe pipesystem without affecting the basic lay-out, more work orcomplicated drawings.

The following pages give examples of many different lay-outsand configurations.

The drawings are made up showing straight pipes in principle butany shape of network can be monitored.It is also simple to expand a pipesection at any point and withany dimension of pipe.

Planning Guide


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There are some very simple rules when working with and plan-ning for a pipe-installation with CWA Alarm System:

1. The alarmwire is connected in each fieldjoint in such a way

that the wire is forming a loop. That requires that the two wiresare kept strictly LEFT and RIGHT without crossing each otherat any point (fig 1).

2. The left wire is ALWAYS on the left side of the pipe andkeeping that position throughout the entire system.The same is valid for the right hand wire.

3. The above is valid at any of the pipesection and at all start/ endpoints.

Planning of anAlarmsection


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The expansion of an existing system can be made at ANY pointalong the piping keeping the 1000 m of pipe-length in mind.

Some rules are imperative:

1. Keep the wires separated and organised so that the correctloop can be formed.

2. Keep good records on the position of the expansion and makesure that it is being noted on the reference drawing.

3. The actual channel of the Alarm Unit has to be “Cold Started”again, to read the new data created by the expansion of the pipe-system.

Expansion of asystem


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The termination of the pipe ends can be done in two differentways both faciliating simplicity and accessibility and still formingthe loop of the alarm wire.

The wires can be looped as fig. 1 shows, crimped and solderedtogether. The loose ends can be bent and pushed into the foam asa mechanical fixture.

If specifications require the use of Endcaps at pipe ends it isnecessary to take out the sensorwires according to fig. 2. This isdone to make future service easier.

Pipe Ends


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The expected life-time of the entire pipe system is 30 - 40 years.

The alarm system is a “state of the art” equipment. The purposeof the system is to indicate and locate an eventual leak in the

piping system.To perform this task over the expected life-time, the followingcriteria have to be met:

1. The wires must be free from mechanical defects.2. All wire-joints have to be BOTH crimped and soldered.3. All joint activators must be installed properly.4. Joint activators must be kept DRY, prior to the foaming.5. All checking procedures must be followed and done.

The Leak Detection System is indicating the following types of faults:A. Leaks inside the joint (Welds).B. Leaks from outside caused by damaged shrinks etc.C. Shorts between wire and carrier pipe.D. Breaks in the wires.

The enclosed instructions are based on experience from over 20years and installations from all over the world. Millions of jointshave been made successfully by following these instructions.Welcome to the society of successful CWA users.

1. The wires shall be connected to a loop comprising max.1000 m of pipe = 2000 m of wire.2. The system is based on a “ left and right” wire principle. Leftwire shall always be kept left and branched off to the left in aT-junction (T-piece).The same is valid for the right-hand wire.3. The joint activator is hygroscopic and sensitive to moisture,rain, flooding and condensation. Keep them dry and protected atall times.4. Complete the field joint as soon as possible after having in-stalled the joint activator.5. Make the electrical checking of the wires to a standard proce-dure that is never forgotten.6. When a pipesection is completed:

Installation

Important Notes

Always, make a check with the portable fault locator.Testing and checking is always expensive!No control can be disastrous and very costly.


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The installation of the alarmwires is expected to take placeunder dry conditions. The joint Activators are hygroscopic andmay absorb moisture or water if handled incorrectly.After the application of the Joint Activators, the field-joint shall

be foamed immediately to avoid moisture due to condensation,rain or flooding. The installation procedure is described indetail in other documents. The following two measurementsshall be made upon finalization of a pipesection in additioninstallation measuring:

1. Testing of loop resistance.Normal value is 1,5 Ohm / 100 m, +/- 10% is permitted.

2. Testing of insulation resistance

Normal value is between 500 kOhm and 200 MOhm,depending on pipelength and weather-conditions.

A final test with TDR, portable Fault Locator, is recommended.

Lowest allowed value is 200 kOhms at 1000 m pipe.LAV (Lowest Allowed Value) can be calculated by using thefollowing formula:

200000 x L

Where: R all = Lowest allowed Resistance value at pipelengthx L m x L = Tested length of pipe shorter than 1000 m.

200 MOhm is = Absolutely Dry Insulation.

Example: 400 m of pipe gives R all = 500 kOhms.

Testing of installedalarm wires

R all =


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TESTCERTIFICATEPipe section identification ..................................................

Pipe identification ..............................................................Test of loop resistance ....................................................... Ohm

Test of insulation resistance ...............................................kOhm Left wire

Test of insulation resistance ............................................... kOhm Right wire

TDR testing performed (if appl.) .......................................

Tested by: ..........................................................................Date .... / ..../ ....

Supervisor: ......................................................................... Date .... / ..../ ....

Cheif Supervisor: ............................................................... Date .... / ..../ ....

Approved by: .....................................................................Date .... / ..../ ....

Instrument battery and setting is checked

by: ...................................................................................... Date .... / ..../ ....

TDR ReadOut: Right Wire

TDR ReadOut: Left Wire

TDR printout for left wire to be placed her

TDR printout for right wire to be placed her


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MANUFACTURERCWA SYSTEM AB

S 131 04 NACKA SWEDENTEL +46 8 556 15 390, FAX +46 8 556 15 391

1

CWA 6103

Application: District Heating.

A pipe alarm unit for monitoring 1000 m ofpipe.Galvanically isolated from carrier pipe andmains for maximum dependability and relia-bility over the years.Measuring method is a combination of Impedancemeasurement and resistance measurement which hasproven to be extremely accurate.

3 different alarm levels are available by a toggle-switch,selectable by customer, due to local requirements.

Equipped with indicating LED for Power, Leak, Fault(break) and Short-circuit. Buzzer and relay will beactivated upon any of these functions.

Protection: IP 65.Built-in protection against lightning and transients.(Patented).Test switch for all functions 110 or 220 V, 50-60 Hz.Outgoing relay with NO/NC contacts Capacity 1000 m ofpipe.Temperature range: -30 - +60 o C.

Weight: 0,850 kg

Size: 175 x 175 x 75 mm.


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QUICK REFERENCE FOR CWA 6000 AND ACCESSORIES.

2001-05-31

CWA 6000 is an alarm system for DISTRICT HEATING PIPES with directapplied insulation of Poly Urethane Foam (PU).

The system is designed to indicate a fault in the pipe consisting of ingressof water or a leak in the carrier pipe as well as a break of the detecting wireor a short between the wire and the pipe.

The different fault conditions are indicated with 2 red Light Emitting Diodes(LED) and a buzzer signal. The alarm condition is also activating a relaywith potential free NO/NC contacts for alarm transmission 'to a central point.

The system consists of the following parts and accessories:

1. ALARM UNIT CWA 6303.

An alarm unit for 1000 m of pipe, galvanically isolated from pipe groundand mains power supply for maximum reliability.

The measuring method is a combination of Impedance measurementand Resistance measurement, thereby offering the highest level ofsecurity and accuracy.

Three different alarm levels are available and can be set by the userwith a toggle switch; 30, 15 and 8 K Ohms, Resistance value equals to150 K Ohms actual resistive DC value.

A separate switch for testing the monitoring functions is present on thefront board.

2. The alarm wire (detector wire) is an un-insulated solid copper wire of1.5 mm sq. or 1,3mm diameter. This wire is placed 15 - 20 mm fromthe pipe in the foam insulation. The wire is placed horizontally at 3 and

9 o'clock giving 2 wires in each piece of pipe.


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The wires in each pipe are then connected to the next pipe till the totalof1000 m of pipe is reached.The wires are connected in a way that they form a loop, controlling theentire pipe section including all branches and fittings.

3. In each pipe-joint, the wire is embedded in a "Joint Activator" to assurethe exact distance between wire and pipe before and during foaming aswell as enhancing an eventual leak location with a portable TDR.

MEASUREMENTS:175 x 175 x 75 mm, Weight 0,85 kg.

ELECTRICAL : 220 V AC, 50-60 Hz connection.LED for Power, Alarm, Loop break and Short.Switches for TEST and 3 different alarm levels.


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ADJUSTING LEAK DETECTOR - CWA 6103

ADJUSTING ALARM UNIT 6103 AFTER INSTALLATION

1. Connect the power to the terminal marked "Power".

2. The "Power" and "Break" LED’s should light, the buzzer should sound and therelay is trigged.

3. Connect the loop (or a short piece of wire) to connections 4 and 5 in the terminalmarked "LOOP PIPE".The "Break" LED should go out, the buzzer stop and the relay should go back tonormal position.

4. Make sure the Alarm Level switch is in its 30k-position.

5. Move the test-switch to the "Test Moisture" position. After a few seconds the"Alarm Moisture" LED should light up. The LED should go off when the switch isreturned. If this does not work, adjust the alarm level according to the instructionsbelow.

6. Move the test-switch to the "Loop test"-position. The "Loop Alarm" LED shouldlight up.

7. Relay:By changing a jumper on the PCB, it is possible to switch betweenNO and NC functions for the relay. Jumper right equals the NO function andJumper left equals the NC function.

8. Buzzer:To turn off the buzzer the "I'' jumper below the buzzer is broken.

9. Adjusting the alarm levels.

30 K Ohm

Connect the loop to the Pipe Connection terminal and set the alarm-level selectorin the 30k position.


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If the LED is lit, adjust R31 so that the LED goes off. Move the Test-switchupwards (Test Moisture) and keep it there. Adjust R31 slowly until the LED is litagain.

15 and 8 K Ohm

These levels are adjusted from factory and a check is performed in the followingway:

15 K Ohm

Move the Alarm Level Switch to the 15 K Ohm position. Connect an external 15K Ohm resistor between points 5 and 6 on the plinth for loop-connection. The

Alarm LED should now light up within a second or two. If not, adjust thepotentiometer for 15 K Ohm (R52) until it does.

8 K Ohm

Move the Alarm Level Switch to the 8 K Ohm position. Connect an external 8 KOhm resistor between points 5 and 6 on the terminal for loop-connection. The

Alarm LED should now light up within a second or two. If not, adjust slowly thepotentiometer for 8 K Ohm (R53) until it does.

leak detection_dc pipe

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