LEAK DETECTION

INSTALLATION
AND
OPERATION 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 TEST

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

Operation instructions
CWA 9000
Also refer to project manual for specific data.

Start up

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

Monitoring

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

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

NOTE:
before THE START-UP, it is necessary to have checked the
whole pipesection according to the installation/testing
instructions.
It is also advised that all reference-points have been established
and the appropriate forms have been filled-in.
Make sure that all as-built-drawings are properly up-dated with
all
Compensators, Tees and Elbow marked, all distance measurements are noted on the same. All drawings should be available
during 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 you
on the proceedings step by step and it will be simple to follow
the instructions.

To start the unit:

Connect the wires/cables to monitor.
Connect the mains power according to appropriate Terminal
Block Configuration paper.

1. Unit equipped with BBU

The 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 released.
Press down all fuses.
The unit will start up and the displays backlight is on.
Display reads:
VER. 4.20
COMADS. xx
ANY KEY TO PROCEED

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

eo553

Leak detector frontplate

Used configuration in the examples.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

Selfcheck

The background light in the LCD display is active during the

whole Start-up procedure.

VER. 4.20
COMADS. xx
ANY KEY TO PROCEED

COPYRIGHT
CWA SYSTEM AB
1988 - 1993

THIS UNIT IS EQUIPPED

WITH x CHANNELS
<F> TO PROCEED

PRESS:

Appears when the unit is coldstarted (Started for the first

time).
xx corresponds to the communication address if applicable.

This is shown for about 5 sec

during the selfcheck.

x corresponds to the number of

analog boards installed
(channels).

SETTING UP CHANNEL
NUMBER 1

The unit makes initial measurements on Channel 1.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

Sensitivity setting

The unit has four different sensitivity levels. The sensitivity level
that shall be used depends on what kind of liquids that are to be
monitored and the type of sensor cable/wire that is being used.
Sensitivity <1> is most sensitive and <4> least sensitive.
[For District Heating sensitivity <4> is recommended.]
For other applications, refer to project manual.
The unit will ask for the sensitivity setting for each channel
installed individually.

SET SENSITIVITY CH.1

<1>,<2>,<3>,<4>

Example: PRESS:

Press the number that corresponds to the sensitivity that

shall be used for channel 1.

CHANNEL 1
SENSITIVITY <4>

If not OK, press button 1 - 3

to make correct setting.

M/R TO ACCEPT

[Press M/R only when setting is

correct.]

The sensitivity settings must be

made for all the installed
channels individually.
You will be prompted.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

Propagation speed

The unit has to know the propagation speed for each installed
channel and its cable.
For District Heating with direct applied foam, propagation speed is
usually 91%.

SET PROPAGATION
SPEED FOR CHANNEL 1
ENTER 3 DIGITS
REL. SPEED =

This is where you tell the unit the

basic electrical value of the
cable to be monitored.
See cable specifications.
The value shall be set with 3
digits and is the relative pulse
propagation speed in % of the
speed of light.

This value is a good

start for most preinsulated pipes. We
recommend that you
also use the
function:
"Adjust
propagation
speed"

Example: 91%

PRESS:

SET PROPAGATION
SPEED FOR CHANNEL 1
ENTER 3 DIGITS
REL. SPEED = 0,910

to get accurate
readings in case of a
leak.

INITIALIZING ch:1

After having entered the propagation speed, the unit automatically

INITIALIZES itself, stores the
given values in the memory and
makes a new self check.
This sequence is ended when unit
presents: CABLE END FOUND
AT xxxx

This procedure may take some

time depending on cable length.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

Cable end

CHANNEL 1:
SET UP TO MONITOR
860 METERS
<F> TO PROCEED

The unit presents the distance to

the cable end. This value is not
exact, but should correspond to
the physical length within
- 0% / + 10%.
See fig.
Fill out the given value in the
Start-Up Form.

NOTE:
Later on in the start-up procedure, it is possible to adjust the
propagation speed to get the exact cable length corresponding to
the physical length of the pipe system.
Differences greater than + 10% at this stage are unusual. If the value
is 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 the
cable.
Check with TDR.
The echo from the open end can also be too small, due to impedance
mismatches on the cable.
Check with TDR.
Example:
Physical length = 860 meters
Given value = 530 meters
Check with TDR and repair.
After having the right distance displayed:
PRESS:

F
EO557

Figure: Cable End presention.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

Measuring Line

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

MEASURING LINE 1

COMPUTING LIMITS

CH. 1
OFFSET ZERO ?
<F>=YES <R>=NO

Wait while the unit measures the

cable and stores the digitized
values for every timeslot in the
memory.

Wait while the unit is computing

UPPER and LOWER ALARM
LIMITS, and storing those
values in the RAM memory.
This is also a slow procedure, it
can take about 2 min./ 100
meters.

After completion of the Measuring Line sequence the display

will read.

EO558

Figure: Computing limits.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

Offset zero

The OFFSET ZERO function is used when you have the Leak
Detector unit installed far away from the startpoint of the sensor
wire 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 function
enables the Jumper Cable to be integrated into the unit so that
the measuring starts at the connection point at the pipe.
NOTE:
A Break or a Short along the Jumper Cable will be displayed as a
negative value on the LCD display.
Example: [ BREAK AT -47 m ] means that the break is at 47 m
from the desired ZERO POINT towards the Leak Detector.

CH. 1
OFFSET ZERO ?
<F>=YES <R>=NO

The display gives 2 choices:

ALT. A:
Let the unit measure the entire
cable from the connectors in
bottom of the unit.
If the unit is equipped with more
than one channel the next step
will be sensitively setting for
next channel. i.e Ch. 2 ,3 ,4
See page LE. 9: 14.

PRESS:

PRESS:

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

EO559

Figure: OFFSET ZERO Not in function

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

10

Offset zero yes

Alternative B:
If you have an installation where different cabletypes with different 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 different
electrical characteristics and propagation speeds and therefore
will give erroneous distance values in case of a Leak/Break
alarm.

DISCONNECT CABLE 1
AT THE DESIRED ZERO
POINT THEN PRESS
ANY KEY TO PROCEED

Disconnect the cable at the

desired Zeropoint (usually the
matchingbox).
Disconnect AFTER
matchingbox, not the BNC
connector.

The display gives the distance to

ZERO POINT LOCATED
the Zeropoint.
67meters
FROM THIS UNIT
Fill out the given value in the
ANY KEY TO PROCEED
Start-Up Form.
PRESS:

any

RECONNECT CABLE
AT ZERO POINT THEN
ANY KEY TO
CONTINUE

PRESS:

Reconnect the cable at the

Zeropoint.
If the unit is equipped with more
than one channel the next step
will be sensitively setting for next
channel.

any
Go to page LE. 9: 14 and proceed from there.
EO5510

Figure: OFFSET ZERO in function

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

11

Offset Zero and Cable

End when MB CWA
9092 is installed

Cable End
Offset Zero
Normal

To make the start up procedure easier the Matching Box CWA

9092 is equipped with a 3-way switch. The 3 positions are used in
the following way:
Never operate this switch except during "Start-Up"
procedure.

1. Normal
The normal position. Check that the switch is set in this position
before the start up procedure is started.
The switch shall also be in this position in monitoring mode.
CWA 9000

Closed

Pipe with sensorwires

Open

Cable End
Offset Zero
Normal

2. Offset Zero
The switch makes a break at the beginning of the leak detection
loop. Used when the Offset Zero point shall be detected.
When the unit prompts you to "disconnect the cable at desired
zero point", set the switch in this position.
When the unit prompts you to "reconnect the cable", set the
switch back to Normal position.
CWA 9000

Open

Pipe with sensorwires

Open

Cable End
Offset Zero
Normal

Do NOT forget to
set switch in
"NORMAL"
position.

3. Cable End
The switch makes a short at the end of the leak detection loop. Used
when the Propagation speed shall be adjusted.
When the unit prompts you to "short the far end of the cable(s)to
be adjusted", set the switch in this position.
When the unit prompts you to "remove the shorts at cable
ends", set the switch back to Normal position
CWA 9000

Closed

Pipe with sensorwires

Closed

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

12
LE.9:17:

Adjust propagation
speed

When all the installed channels are initialized, it is possible to

adjust the propagation speed until the reading on the display
corresponds to known physical length of the cable/sensorwire.

ADJUST PROPAGATION
SPEED FOR CABLES
<F>=YES <R>=NO

If no adjustment is desired
PRESS:

You have two choices:

ALT. A:
If no adjustment is necessary
press <R> and the unit will
proceed into MONITORING
MODE, see page LE. 9: 23.

If adjustment is desired
PRESS:

SHORT THE FAR END

OF
THE CABLE(S) TO BE
ADJUSTED
ANY KEY TO PROCEED

PRESS:

any

CHANGE SPEED FOR

CHANNEL NO.

ALT. B:
If, for example, the propagation
speed for channel 1 shall be
adjusted:
Make a temporary short at the
far end(s) of the cable(s).
NOTE:
It is recommended to make a
short at all wires/cables at the
same time.

Press the number that corresponds to the channel that shall

be adjusted.

<F> TO PROCEED

EO5511

Figure: Adjust Propagation speed function.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

13

Adjust propagation
speed

PRESS:

First, try with the same propagation speed as initiated ( 910 ).

SET PROPAGATION
SPEED FOR CHANNEL 1
ENTER 3 DIGITS
REL. SPEED = 0.

Example: 9

SET PROPAGATION
SPEED FOR CHANNEL 1
ENTER 3 DIGITS
REL. SPEED = 0.910

MEASURING LINE

CHANNEL 1:
CABLE END FOUND AT
733meters
ANY KEY TO PROCEED

PRESS:

any

CHANGE SPEED FOR

CHANNEL NO.
<F> TO PROCEED

The unit presents the new distance to the shorted end.

NOTE !:
If the OFFSET ZERO function
is used, the distance from the
ZERO POINT will be
displayedwhen changing the
propagation speed.
The displayed length is 13 m
longer than the correct length in
our example.

Enter the number of next

channel (if applicable).
Enter <F> to proceed to next
function.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

14

Adjust propagation
speed

The read-out from the display was a little to long and therefore it
is necessary to make a new adjustment.
For the calculation of the right propagation speed the following
rule can be used.
Displayed length < The correct length : Use a higher propagation
speed.
Displayed length > The correct length : Use a lower propagationspeed.
In our example we shall accordingly use a slower propagation
speed.
PRESS:

Since the new reading was not

correct, try with new values until
a correct value is displayed.

SET PROPAGATION
SPEED FOR CHANNEL 1
ENTER 3 DIGITS
REL. SPEED = 0.

PRESS:

any any any

5-9 0-9 0-9

CHANGE SPEED FOR

CHANNEL NO.
<F> TO PROCEED
PRESS:

REMOVE SHORTS AT
CABLE ENDS

When the displayed length is

correct for the first channel the
next channel can be adjusted by
pressing the button corresponding to the channel number.
When all channels are adjusted.

The unit will remind you to

remove the shorts.

ANY KEY TO PROCEED

Background light off
TIME: 25 FEB 13:51
MONITORING CHAN. 1

Initializing procedure is now completed. The unit monitors

channel 1, this is the normal working mode. When monitoring
more than one channel, the unit changes channel number
according to the channel that is being monitored.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

15

The security codes are implemented to prevent un-authorized

tampering with the pipe alarm system, thereby securing that all
messages and alarms are being handled by authorized persons.

User numbers and

security levels

Level

USER
NUMBER
00

ACCESS TO
<1>:DISABLE CHANNEL
<2>:ENABLE CHANNEL
<3>:SET CLOCK
<MR>:EXIT,<F>:MORE

01

<1>:SET PASSWORD
<2>:CLEAR ALARMTABLE
<3>:SET COLDSTART
<MR>:EXIT

02

03
04
05
06
07
08
09

<1>:DISABLE CHANNEL
<2>:ENABLE CHANNEL
<3>:SET CLOCK
<MR>:EXIT

10
3

Reset

Read Memory

50

Open

USER NUMBER and ACCESS CODE table.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

16

User numbers and

access code

Now it is advisable to set desired individual USER NUMBERS

and ACCESS CODES (pass words). This can ONLY be done by
some one with user no. 00, 01, 02.
The access codes can be programmed individually and we suggest that you use a code which is easily remembered.

TIME: 25 FEB 13:51

MONITORING CHAN. 1

PRESS:

Normal display.

The unit is delivered with DEFAULT ACCESS CODE for

USER NUMBER 00.
The ACCESS CODE is 10000.

Background light on
ENTER USER NO. 00
ENTER ACCESS CODE

You can change also that code

to anything you like if the value
is less than 64000.

ENTER USER NUMBER:

If you enter the wrong ACCESS

CODE for a USER NUMBER ,
you will be notified with the
message: [NOT VALID !].
You must start over again, by
pressing the <F> key.

ENTER ACCESS CODE:

1

Default.

ENTER USER NO. 00

ENTER ACCESS CODE
*****

<1>:DISABLE CHANNEL
<2>:ENABLE CHANNEL
<3>:SET CLOCK
<MR>:EXIT ,<F>:MORE

Choose function.

MENU 1

PRESS:

<1>:SET PASSWORD
<2>:CLEAR ALARMTABLE
<3>:SET COLDSTART
<MR>:EXIT

Choose function 1.

MENU 2

PRESS:

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

17

Set password

The security levels are divided into three groups and one free
which is open for all persons. The USER NO. gives the
accessible security levels. See page LE. 9: 23.
USER NUMBER: 00, 01, 02 have access to all functions and
commands including setting USER NUMBERs and ACCESS
CODEs.
USER NUMBER: 03, 04, 05, 06, 07, 08, 09 have a limited
access but can handle the following:
DISABLE/ENABLE CHANNEL, SET CLOCK and RESET
ALARM.
USER NUMBER: 10 - 49 can only RESET ALARM.

You are prompted to enter your

USER NUMBER.
As an example 00.

ENTER USER NO.

ENTER:

ENTER USER NO. 00

ENTER USER NO. 00

ENTER CODE, 5 DIGITS
MAX NUMBER=64000

The highest ACCESS CODE is

64000.
Do not exceed that value.

ENTER:
1

As an example.

Background light off

TIME: 25 FEB 13:51
MONITORING CHAN. 1

Proceed with the following user

numbers in each security level
as described above.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

18

Set clock

The unit is equipped with a clock and full calendar.

Setting the clock to actual values is described in this part.
TIME: 25 FEB 14:51
MONITORING CHAN. 1

PRESS:

Background light on
<1>:DISABLE CHANNEL
<2>:ENABLE CHANNEL
<3>:SET CLOCK
<MR>:EXIT ,<F>:MORE
PRESS:

Enter USER NUMBER

Enter ACCESS CODE
Choose function <3>.

Time: 26 Feb 14:34

<F>=SET TIME
Allotherexit
Set month Feb

=+ =-,<MR>=EXIT
Set day 26

The display now presents the

date, month and time ( 24 hour ).
The date may be right but the
time has to be set unless correct.
Use the arrow keys to change
month.
= UP
= DOWN
Press <M/R> for next window.
Use the arrow keys to change
day.

=+ =-,<MR>=EXIT
Set hour 14

Use the arrow keys to change

hour.

=+ =-,<MR>=EXIT
SetMinutes

Use the arrow keys to change

minutes.
Press <M/R> to exit.

=+ =-,<MR>=EXIT
Background light off
TIME: 25 FEB 13:41
MONITORING CHAN. 1

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

19

Alarm test

You are recommended to make at least one Alarm Test to verify

that everything is OK with the installation and entered values.
TIME: 25 FEB 13:41
MONITORING CHAN. 1

Background light is flashing

ALARM CHANNEL :1
TIME: 25 FEB 14:06
LEAK 137 meters
PRESS <R> TO RESET
PRESS:

A/I

PRESS:

<R> RESET
will Reset the alarm.

PRESS:
1

PRESS:

After a while, depending on the

length of the wire and distance to
alarm and number of channels,
the alarm will sound and the
display shows for example :
<A/I> ALARM INHIBIT
will silence the buzzer and
release relay. <A/I> will look the
display and keep the backlight
on.

ENTER USER NO. 00

ENTER ACCESS CODE
*****

PRESS:

Simulate a fault by shorting the

cable somewhere along the line
where the sensorwire/cable is
easily accessible (Reference
point).
You can use anything that fits.

Background light is off

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

The unit will now ask for your

user number.
Enter your USER NUMBER
and ACCESS CODE.

ENTER USER NUMBER

or any you have previously
entered.
ENTER ACCESS CODE
or what you have previously
entered.
For Reset.
The alarm is Reseted and the
unit is back into normal
working mode except for that
it only monitors the cable up
to the fault minus 3 meters.
The alarm is still stored in the
memory and can be recalled
whenever needed.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

20

Alarm memory

All alarms are stored in the battery backed memory and can be
recalled whenever needed.
The ALARM TABLE can also be erased and we advise you to
do so before turning over the installation to the owner, thereby
ensuring that all future alarms are ALARMS trigged after
installation.

PRESS: M/R

Background light is on
EXAMINE WHICH
CHANNEL

PRESS:

CH.1 ENTRY NO. 1

TIME: 25 FEB 14:36
LEAK 137 meters
PRESS MR TO EXIT

PRESS: M/R

CH.1 LAST ENTRY

TIME: xx FEB 14:36
LEAK xxx meters
PRESS MR TO EXIT

Press the number that corresponds to the channel number

to be examined.

Or any other installed (2,3,4)

you want to examine.

If there are more alarms , they

can be displayed by using the
arrow keys. It is possible to
scroll up and down in the
table.

To exit the alarm table mode.

Indicates that there are no

more messages in the table in
question.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

21

Clearing alarmtable

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.

Background light is off

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

PRESS:

To clear an alarmtable.

Background light is on
ENTER USER NO.

PRESS:

Enter your user number.

ENTER USER NO. 00

ENTER ACCESS CODE

PRESS:
1

ENTER USER NO. 00

ENTER ACCESS CODE
*****

Enter your access code.

If the entered USER NUMBER

and ACCESS code corresponds
with the stored codes, it gives
access to MENU 1.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

22

Clearing alarmtable

<1>:DISABLE CHANNEL
<2>:ENABLE CHANNEL
<3>:SET CLOCK
<MR>:EXIT ,<F>:MORE

Choose function <F>.

For menu 2.

Menu 1

PRESS:

<1>:SET PASSWORD
<2>:CLEAR ALARMTABLE
<3>:SET COLDSTART
<MR>:EXIT

Choose function <2>.

Menu 2

PRESS:

PRESS <R> TO CLEAR

TABLE NO. 1
KEEP PRESSED TO 1000
999

PRESS:

For [ CLEAR ALARMTABLE ]

function.
For your own protection, the
memory can not be cleared just by
pressing one key.
As the display says, hold the <R>
pressed while a counter goes from
0, counting up to 999.
If you release the button before
1000 is reached, you have to start
over again.

The alarmtable is now empty and the unit is monitoring the entire
length.
If the fault that caused the alarm is not repaired, a new alarm will
be trigged.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

23

Disable channel

It is possible to disable one or more channels.

This function shall/can be used while repairing a fault.

Time: 26 Feb 14:27

MONITORING CHAN. 2

PRESS:

Enter USER NUMBER

Enter ACCESS CODE

Background light is on
<1>:DISABLE CHANNEL
<2>:ENABLE CHANNEL
<3>:SET CLOCK
<MR>:EXIT,<F>:MORE

PRESS:

Choose function <1>.

MONITORING
NELS
1,2

CHAN-

You can disable any channel that

is installed.

CHANNEL TO DISABLE

PRESS:

MONITORING
NELS
2,

If you intend to disable channel

1.
CHAN-

CHANNEL TO DISABLE

NOT MONITORING
ALL CHANNELS DISABLE

The display tells which

channel(s) that is being
monitored.
If you disable all installed channels the display warns you by
telling:

THE UNIT IS NOT MONITORING.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

24

Enable channel

After having disabled any channel for some reason, you have to
enable 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 and
repaired the same.
Time: 26 Feb 14:27
MONITORING CHAN. 2

PRESS:

Background light is on
<1>:DISABLE CHANNEL
<2>:ENABLE CHANNEL
<3>:SET CLOCK
<MR>:EXIT,<F>:MORE

PRESS:

Choose function <2>.

You can enable any channel

that is installed.

MONITORING
CHANNELS
2
CHANNEL TO DISABLE

PRESS:

Enter USER NUMBER

Enter ACCESS CODE

If you intend to enable channel

1.

MONITORING
NELS
1,2

CHAN-

The display tells which

channels that is being
monitored.

CHANNEL TO ENABLE
Background light is off
Time: 26 Feb 14:28
MONITORING CHAN. 1

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

25

Error codes

An error message will be displayed if there is any fault on the

analog board(s) in the unit, or if you have a fault on the first 10
meters of the detector cable or Jumper cable.
NOTE: An ERROR message automatically DISABLES the
channel in question.
Background light is flashing.
* ERROR * ERROR *
CHANNEL NO. 1
IS FAULTY
AND DISABLED
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).

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

26

 CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

27

 CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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 CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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 CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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 CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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CWA Heater Unit

Application: Heating element for use in Leak Detectors whenever the environmental temperature is
expected to be lower than 0 C.
Space is reserved on mounting plate. Thermostat is included.

Specification: CWA Heater Unit

Mechanical:
Dimensions:
Weight:
Electrical:
Power:
Power consumption:
Connection:

115 x 70 x 50 mm
300 grams
230 VAC
33 Watt
Connect to mains terminal block and
thermostat.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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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 a
risk of for earth currents and transients. Those signals can
damage electronic parts and systems.
CWA 9091 MATCHINGBOX is designed to drain such signals
to ground and also to match the signals from the Leak Detector
to smoothly pass over to the sensor wires or cables. It is a small
but important unit.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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CWA 9092

Application: District Heating

The Matchingbox is connected between the alarmunit and the
alarmwire (sensorwire) at the startpoint of every pipesection.
The purpose is to match the transmitted pulse from the alarm
unit to the impedance of the alarmwire as well as galvanically
isolate the alarmunit from the wire and pipe.

Specification: CWA 9092

Power:
Size:
Weight:
Temperature range:
Input:
Output:
Protection Class:

Not applicable
180 x 80 x 56 mm
750 grams
-10 - +70 C.
BNC connector 50 Ohm
Connection cable 1,25m, mounted
IP 65

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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NOTE: See also PDF file CWA 9092, Matching

Box for details

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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

Offset Zero and Cable

End when MB CWA
9092 is installed

Cable End
Offset Zero
Normal

To make the start up procedure easier the Matching Box CWA

9092 is equipped with a 3-way switch. The 3 positions are used in
the following way:
Never operate this switch except during "Start-Up"
procedure.

1. Normal
The normal position. Check that the switch is set in this position
before the start up procedure is started.
The switch shall also be in this position in monitoring mode.
CWA 9000

Closed

Pipe with sensorwires

Open

Cable End
Offset Zero
Normal

2. Offset Zero
The switch makes a break at the beginning of the leak detection
loop. Used when the Offset Zero point shall be detected.
When the unit prompts you to "disconnect the cable at desired
zero point", set the switch in this position.
When the unit prompts you to "reconnect the cable", set the
switch back to Normal position.
CWA 9000

Open

Pipe with sensorwires

Open

Cable End
Offset Zero
Normal

3. Cable End
The switch makes a short at the end of the leak detection loop. Used
when the Propagation speed shall be adjusted.
When the unit prompts you to "short the far end of the cable(s)to
be adjusted", set the switch in this position.
When the unit prompts you to "remove the shorts at cable
ends", set the switch back to Normal position
CWA 9000

Closed

Pipe with sensorwires

Closed

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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SENSOR WIRES IN
PIPES,
JOINTS AND FITTINGS
1. CWA Crimp Connector
CWA Sensor Wire
CWA Joint Activator
2. Design Guide
3. Planning Guide
4. Installation
5. Testing
Test Format
The Leak Detection / Location system consists of TWO
important parts: The SENSOR WIRE and LEAK DETECTORS.
The installation and connection of the sensorwires is very
important 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 20
years of experience and have proven to be reliable.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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CWA Crimp
Connector

Application: For connecting Alarm wires

The CWA Crimp connector is used for connecting alarmwires by
crimping and soldering.
Use of CWA Crimp Plier is mandatory.

Specification: Crimp Connector

Mechanical: L = 8.2 mm
Inner dia.
3.2 mm
Outer dia.
5.7 mm
Delivered in boxes of 100 pieces.

CWA Sensor Wire

The sensor wire is used in pre-insulated District Heating pipes

where it is placed in the insulation foam 15 - 20 mm from the
carrier 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 Crimp
Connector.
Delivered from CWA or Local.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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CWA Joint Activator

Application: For District Heating joints

Is used in the joints to secure the alarm wire at a certain distance
from the pipe during foaming of the joint.
Made of specially treated felt which is heat resistant.

Specification: CWA Joint Activator

Mechanical:

L = 400 mm
W = 100 mm
T = 10 mm

Delivered in boxes of 100 pieces.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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Design guide for

pipes and fittings
with CWA alarm
systems

Production
Production of pipes and fittings with CWA Sensor Wires is quite
simple and economical. Moreover, very few additional equipment is necessary to run a smooth and effective production line.
The layout and design can be fully implemented into any existing
production-line.
Investments are minimized and require no extra tooling except
for the wire supports that should be integrated in the present
centering pieces that are being used in current production.
The use of specified copper wires, which are available as
standard from local suppliers, reduces the cost/pipe to minimum.
All pipes and fittings are fully symmetrical and can be tailored to
any measurement or produced as standard parts that are interchangeable with each other and within wide ranges of pipediameters.
Pipesizes over 250 mm are recommended to have 4 sensor wires
for 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.

CWA Sensor Wire

The sensor wire is used in pre-insulated District Heating pipes

where it is placed in the insulation foam 15-20 mm from the
carrier 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 Connector.
Delivered from CWA or Local.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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Straight Pipes

The manufacturing of straight pipes is described under part

Manufacturing.
Distance between sensorwire and pipe is min. 15 mm / max. 20
mm.

Elbows

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 to
pass (above or under) obstacle.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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T-pieces

T-pieces always carry 3 wires. One wire goes straight through

and the other wires form the T.
T-pieces can be placed in left or right hand position without
affecting the function or principle in lay-out.

Compensators

The compensator is manufactured with more wire than the actual

mechanical length.
That length is important and is noted on the individual compensator.
Length differs also depending on diameter.
Wire can be laid spirally wound or in a loop. Both giving the
possibility of movements.

NOTE:

As the compensator carries more wire than its mechanical

length, the position of the compensator and the length of its
built-in wire MUST BE NOTED on the as-built-drawing.
Otherwise, problems will occure in faultlocation.

Important

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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Planning Guide

The CWA 9000 System is based on very logical and easy to

understand lay-outs of the sensor wires. It makes it possible to
monitor any pipe-layout in any environment.

The Leak Detector can be placed and replaced anywhere along

the pipesystem without affecting the basic lay-out, more work or
complicated drawings.

The following pages give examples of many different lay-outs

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

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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Planning of an
Alarmsection

There are some very simple rules when working with and planning 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 wires
are kept strictly LEFT and RIGHT without crossing each other
at any point (fig 1).
2. The left wire is ALWAYS on the left side of the pipe and
keeping 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.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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Expansion of a
system

The expansion of an existing system can be made at ANY point

along 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 correct
loop can be formed.
2. Keep good records on the position of the expansion and make
sure 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 pipesystem.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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Pipe Ends

The termination of the pipe ends can be done in two different

ways both faciliating simplicity and accessibility and still forming
the loop of the alarm wire.
The wires can be looped as fig. 1 shows, crimped and soldered
together. The loose ends can be bent and pushed into the foam as
a mechanical fixture.
If specifications require the use of Endcaps at pipe ends it is
necessary to take out the sensorwires according to fig. 2. This is
done to make future service easier.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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Installation

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

The alarm system is a state of the art equipment. The purpose
of the system is to indicate and locate an eventual leak in the
piping system.
To perform this task over the expected life-time, the following
criteria 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 20
years and installations from all over the world. Millions of joints
have been made successfully by following these instructions.
Welcome to the society of successful CWA users.

Important Notes

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. Left
wire shall always be kept left and branched off to the left in a
T-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 at
all times.
4. Complete the field joint as soon as possible after having installed the joint activator.
5. Make the electrical checking of the wires to a standard procedure that is never forgotten.
6. When a pipesection is completed:
Always, make a check with the portable fault locator.
Testing and checking is always expensive!
No control can be disastrous and very costly.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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Testing of installed
alarm wires

The installation of the alarmwires is expected to take place

under dry conditions. The joint Activators are hygroscopic and
may 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 in
detail in other documents. The following two measurements
shall be made upon finalization of a pipesection in addition
installation 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 the
following formula:
R all =

200000
xL

Where: R all = Lowest allowed Resistance value at pipelength

x 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.

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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TESTCERTIFICATE
Pipe 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: Left Wire

TDR printout for left wire to be placed her

TDR ReadOut: Right Wire

TDR printout for right wire to be placed her

CWA SYSTEM AB
P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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P.O. Box 4007, S-131 04 NACKA, SWEDEN

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CWA 6103
Application: District Heating.
A pipe alarm unit for monitoring 1000 m of
pipe.
Galvanically isolated from carrier pipe and
mains for maximum dependability and reliability over the years.
Measuring method is a combination of Impedance
measurement and resistance measurement which has
proven 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 be
activated 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 of
pipe.
Temperature range: -30 - +60o C.
Weight: 0,850 kg
Size:

175

175

75

mm.

MANUFACTURER
CWA SYSTEM AB
S 131 04 NACKA SWEDEN
TEL +46 8 556 15 390, FAX +46 8 556 15 391

QUICK REFERENCE FOR CWA 6000 AND ACCESSORIES.

2001-05-31
CWA 6000 is an alarm system for DISTRICT HEATING PIPES with direct
applied insulation of Poly Urethane Foam (PU).
The system is designed to indicate a fault in the pipe consisting of ingress
of water or a leak in the carrier pipe as well as a break of the detecting wire
or 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 relay
with 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 ground
and mains power supply for maximum reliability.
The measuring method is a combination of Impedance measurement
and Resistance measurement, thereby offering the highest level of
security and accuracy.
Three different alarm levels are available and can be set by the user
with a toggle switch; 30, 15 and 8 K Ohms, Resistance value equals to
150 K Ohms actual resistive DC value.
A separate switch for testing the monitoring functions is present on the
front board.
2. The alarm wire (detector wire) is an un-insulated solid copper wire of
1.5 mm sq. or 1,3mm diameter. This wire is placed 15 - 20 mm from
the pipe in the foam insulation. The wire is placed horizontally at 3 and
9 o'clock giving 2 wires in each piece of pipe.
MANUFACTURER
2
CWA SYSTEM AB
S 131 04 NACKA SWEDEN
TEL +46 8 556 15 390, FAX +46 8 556 15 391

The wires in each pipe are then connected to the next pipe till the total
of1000 m of pipe is reached.
The wires are connected in a way that they form a loop, controlling the
entire pipe section including all branches and fittings.
3. In each pipe-joint, the wire is embedded in a "Joint Activator" to assure
the exact distance between wire and pipe before and during foaming as
well 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.

MANUFACTURER
CWA SYSTEM AB
S 131 04 NACKA SWEDEN
TEL +46 8 556 15 390, FAX +46 8 556 15 391

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" LEDs should light, the buzzer should sound and the
relay is trigged.

3.

Connect the loop (or a short piece of wire) to connections 4 and 5 in the terminal
marked "LOOP PIPE".
The "Break" LED should go out, the buzzer stop and the relay should go back to
normal 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 is
returned. If this does not work, adjust the alarm level according to the instructions
below.

6.

Move the test-switch to the "Loop test"-position. The "Loop Alarm" LED should
light up.

7.

Relay:
By changing a jumper on the PCB, it is possible to switch between
NO and NC functions for the relay. Jumper right equals the NO function and
Jumper 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 selector
in the 30k position.

MANUFACTURER
CWA SYSTEM AB
S 131 04 NACKA SWEDEN
TEL +46 8 556 15 390, FAX +46 8 556 15 391

If the LED is lit, adjust R31 so that the LED goes off. Move the Test-switch
upwards (Test Moisture) and keep it there. Adjust R31 slowly until the LED is lit
again.
15 and 8 K Ohm
These levels are adjusted from factory and a check is performed in the following
way:
15 K Ohm
Move the Alarm Level Switch to the 15 K Ohm position. Connect an external 15
K 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 the
potentiometer 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 K
Ohm 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 the
potentiometer for 8 K Ohm (R53) until it does.

MANUFACTURER
CWA SYSTEM AB
S 131 04 NACKA SWEDEN
TEL +46 8 556 15 390, FAX +46 8 556 15 391