CODEL Tunnel Tech 500 Series User manual

CODEL Page 1 Operation and Maintenance
Issue: A Revision:3 Date:16/01/2019 Ref:1003 1
TECHNICAL MANUAL
Tunnel Tech 00 Series
Tunnel Tech 501 – CO/NO/NO2
Tunnel Tech 502 – CO/NO
Tunnel Tech 503 – CO
Tunnel Tech 504 – NO
Tunnel Tech 505 – NO2
Tunnel Tech 506 – CO/NO2
Tunnel Tech 507 – NO/NO2
Tunnel Atmosphere Monitoring System
(CO/NO/NO2)
CODEL International Ltd.
Station Building, Station Road, Bakewell, Derbyshire DE4 1GE United Kingdom
t : [phone] f : [phone] e : [email protected] web : www.codel.co.uk

CODEL Operation and Maintenance Manual
Issue: A Revision:3 Date:16/01/2019 Ref:1003 1

CODEL Operation and Maintenance Manual
Issue: A Revision:3 Date:16/01/2019 Ref:1003 1
CODEL International Ltd is a UK company based in the heart of the Peak District National Park at Bakewell,
Derbyshire. The company specialises in the design and manufacture of high-technology instrumentation for the
monitoring of combustion processes and atmospheric pollutant emissions.
The constant search for new products and existing product improvement keeps CODEL one step ahead. With a
simple strategy, to design well-engineered, rugged, reliable equipment, capable of continuous operation over
long periods with minimal maintenance, CODEL has set standards both for itself and for the rest of the industry.
All development and design work is carried out ‘in-house’ by experienced engineers using proven state-of-the-
art CAD and software development techniques, while stringent assembly and test procedures ensure that the
highest standards of product quality, synonymous with the CODEL name, are maintained.
High priority is placed upon customer support. CODEL’s dedicated team of field and service engineers will assist
with any application problem to ensure that the best possible use is derived from investment in CODEL quality
products.
If you require any further information about CODEL or its products, please contact us using one of the numbers
below or alternatively visit our web site.
t : [phone]
f : [phone]
e : [email protected]k
web : www.codel.co.uk

CODEL Operation and Maintenance Manual
Issue: A Revision:3 Date:16/01/2019 Ref:1003 1

CODEL Operation and Maintenance Manual
Issue: A Revision:3 Date:16/01/2019 Ref:1003 1
Content
1 System Description ......................................................................................................................................... 1
1.1 The Tunnel Tech 00 Series Concept .................................................................................................... 1
1.2 CO, NO, and NO2 ................................................................................................................................... 2
1.3 Power Supply Unit (PSU) ....................................................................................................................... 3
2 Principles of Operation ................................................................................................................................... 4
2.1 Electro Chemical Cell – CO/NO/NO2 ..................................................................................................... 4
3 Specification ...................................................................................................................................................
3.1 Technical data: ......................................................................................................................................
3.2 Construction and Enclosure: ................................................................................................................. 6
3.3 Output and Interface............................................................................................................................. 6
3.4 Compliance and Certification: ............................................................................................................... 6
3. Optional Items ....................................................................................................................................... 7
3.6 Output and Interface: ........................................................................................................................... 7
3.7 Cables .................................................................................................................................................... 8
3.8 Installation Material .............................................................................................................................. 9
4 Installation .................................................................................................................................................... 10
4.1 Mounting Details ................................................................................................................................. 10
4.2 Connections ........................................................................................................................................ 12
Commissioning ............................................................................................................................................. 1
.1 Keypad Membrane .............................................................................................................................. 1
.2 Power Up ............................................................................................................................................. 1
.3 E-Cell commissioning .......................................................................................................................... 16
.4 mA Output Setup ................................................................................................................................ 18
. Relay Output Setup ............................................................................................................................. 20
.6 Time and Date ..................................................................................................................................... 22
6 Maintenance ................................................................................................................................................. 24
6.2 Spare parts .......................................................................................................................................... 28
7 Data Communication .................................................................................................................................... 29
7.1 Hardware Configuration ...................................................................................................................... 29
7.2 Address Numbers ................................................................................................................................ 30
8 List of Figures ................................................................................................................................................ 32
9 Appendix 1: MODBUS Communication & RS48 Connection....................................................................... 33

CODEL Operation and Maintenance Manual
Issue: A Revision:3 Date:16/01/2019 Ref:1003 1

CODEL Operation and Maintenance Manual
Issue: A Revision:3 Date:16/01/2019 Ref:1003 1
IMPORTANT
The warning signs (and meanings) shown below, are used throughout these instructions and are intended to
ensure your safety while carrying out installation, operation and maintenance procedures. Please read these
instructions fully before proceeding.
Caution, risk of electric shock.
Caution, risk of danger.
Caution, hot surface.
Earth (ground) terminal.
Protective conductor terminal

CODEL Operation and Maintenance Manual
Issue: A Revision:3 Date:16/01/2019 Ref:1003 1

CODEL Page 1 Operation and Maintenance
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 1
1Sy tem De cription
1.1 The Tunnel Tech 500 Serie Concept
Tunnel Tech 00 Series is an all-new tunnel atmosphere monitoring system designed exclusively for road
tunnel applications. It offers a family of monitors that provide all the essential measurements necessary to
monitor a tunnel atmosphere for:
- Carbon Monoxide
- Nitric Oxide
- Nitrogen dioxide
This is achieved by using a modular design concept so that the users’ precise monitoring requirements can be
satisfied with a minimum number of components, minimum tunnel cabling and minimum installation costs. It
also offers a variety of data outputs to enable simple acquisition of data.

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 2
The monitoring stations, Figure 1, provide all required measurements and outputs at each monitoring location
within the tunnel.
Figure 1: Tunnel Tech 500 Serie - Monitoring Station
1.2 CO, NO, and NO2
CO, NO and NO2 are measured using electrochemical cell technology. Once the zero level of the cell is set and
recorded in the instrument memory, the cell output is linear and proportional to the ppm or ppb reading.
A serial data link via an RS48 interface allows communication directly with the TunnelTech 00 sensors.
The PSU is required to convert the mains (90-263V AC) supply to the 24V DC required to power the TunnelTech
00.

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 3
1.3 Power Supply Unit (PSU)
The PSU is required to convert the mains (90-263V AC) supply to the 24V DC required to power the TunnelTech
00.
Figure 2: Tunnel Tech 500 Serie - power upply unit 24V DC
mains input
connections

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 4
2Principle of Operation
2.1 Electro Chemical Cell – CO/NO/NO2
In order to measure the level of gas (CO/NO/NO2), the Tunnel Tech 00 uses an electro chemical cell to
convert the gas in to readable data. The gas diffuses in to the sensor and interacts with the electrode within
the cell. This causes a chemical reaction in which the gas is reduced or oxidised. The electrochemical reaction
results in an electric current which can then be read, with the generated voltage being linear to the gas
response, and the detector level is derived from the incoming voltage and subsequently a gas measurement.
2.1.1 E-Cell Calibration
the instruments should be calibrated when it is expected measured gases are zero, this is achieved by purging
the instrument with nitrogen. The instrument can be calibrated by selecting a calibrate mode where, the
instrument records the detector levels during zero conditions which are to be used as reference during normal
measurement.

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 5
3Specification
3.1 Technical data:
Optional
CO NO NO2
Measurement principle: Electrochemical Cell
Measurement units: ppm ppm ppb
Nominal measurement range
(typical):
0 to 800 ppm 0 to 160 ppm 0 to 10 ppm
Measurement range (typical): 1 to 300 ppm 1 to 30 ppm 1 to ppm
Accuracy: ±2 ppm ±2 ppm ±100 ppb
Resolution: 0.1 ppm 0.1 ppm 1 ppb
Response time: 30 seconds
Averaging time: 30 seconds to 3 minutes (Configurable)
Path length: N/A
Operating temperature: + °C to + 0°C (Cell temp)
Humidity: 10-90% R.H
Storage temp: + °C to +2 °C
Nominal power supply: 24V DC
Nominal power consumption: 30W
Interface: 16x2 Display + Keypad
Temperature sensor: On board (PCB)

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 6
3.2 Con truction and Enclo ure:
Aluminium Steel 316 (optional)
Construction: Epoxy Coated Die-Cast Aluminium Stainless Steel 316L or Stainless Steel
316Ti
Colour/Finish: Black (RAL 900 - Jet Black)
(Aluminium)
Silver/Ground, Grain 240 (S/S)
Enclosure Rating: Designed to IP66 (IP69K Optional) Designed to IP66
Weight: 4. kg kg
Outline Dimension: 200 (L) x 230 (H) x 110 (D) (mm) 200 (L) x 2 0 (H) x 1 0 (D) (mm)
3.3 Output and Interface
Communication Port:
No.:
1
Type
:
RS48 MODBUS RTU (Optional)
3.4 Compliance and Certification:
EMC:
Designed to EN61326-1:2006 & EN 0270:2006
Low Voltage:
73/23/EEC (as per datasheet) or 73/23/EEC - Low Voltage and 89/336/EEC -
EMC (as per manual)
Protection:
Designed to IP66
Tunnel Regulation Guidelines:
RABT 2006, RVS 09.02.22 2007

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 7
3.5 Optional Item
24V DC Power Supply
Input:
110 - 240V AC @ 100W Max., 0/60 Hz
Output:
24V DC @ 60W
Dimension:
200 (L) x 230 (H) x 110 (D) (mm)
Colour:
Black (RAL900 - Jet Black)
Construction:
Die-cast Aluminium
Enclosure Rating:
IP66 (IP69K Optional)
Weight:
4.0 kg
3.6 Output and Interface:
Analogue Outputs:
No.: 2 or 4
Type: 4-20 mA
Max. Load: 00Ω
Other: Isolated, fully configurable for CO, NO and NO2
Contact Output:
No.: 2 or 4
Type: SPCO
Max. Load: 00mA @ 60V DC
Other: Configurable as alarm contacts

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 8
3.7 Cable
Recommended Cable Minimum
Specification
Power Supply Cable:
Shielding: Shielded to enclosure
Cores / Wire Diameter: 2 Core / 1mm
Typically Supplied by: Customer
RS48 ModBUS Cable:
Shielding:
Shielded away from enclosure
Cores / Wire Diameter:
2 Core / 0. mm
Typically Supplied by:
Customer
Analogue Output Cable:
Shielding:
Shielded to enclosure
Cores / Wire Diameter:
4 Core / 1mm
Typically Supplied by: Customer
Contact Output Cable:
Shielding:
Shielded to enclosure
Cores / Wire Diameter:
4 Core / 1mm
Typically Supplied by:
Customer

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 9
3.8 In tallation Material
Installation Bolts
Sensor Body:
No.:
4
Dimensions:
180 (L) x 180 (H) (mm)
Bolt Thread Type:
M6
Bolt Length:
60 (mm) or to suit application
24V Power Supply:
No.:
4
Dimensions:
180 (L) x 180 (H) (mm)
Bolt Thread Type:
M6
Bolt Length:
60 (mm) or to suit application
Tunnel Display Unit:
No.:
4
Dimensions:
110 (L) x 140 (H) (mm)
Bolt Thread Type:
M6
Bolt Length:
60 (mm) or to suit application
Note: The TunnelTech 500 PCB are equipped with built-in RS485 communication facilitie for u e during
commi ioning. Thi facility may further be u ed after commi ioning for communication to integrate
the TunnelTech 500 u ing MODBUS protocol – further detail are contained in Appendix A.

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 10
4In tallation
Be ure to ob erve all nece ary afety precaution at all time during in tallation.
All cable gland entry hole are drilled and tapped M20 x 1.5 and are fitted with blanking plug .
Cable gland are to be upplied by the cu tomer according to the cable u ed during in tallation.
4.1 Mounting Detail
After unpacking the equipment check, using the packing list provided, that all items are present. TunnelTech
00 is carried on a fabricated mounting bracket (if supplied)
4.1.1 TunnelTech 500
Secure the TunnelTech 00 to the tunnel wall by the mounting brackets supplied using 4 x M8 bolts (by
others).
Figure 3: TunnelTech 500 – Mounting Dimen ion
4 x holes on latch and hinge for M8
mounting bolts

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 11
4.1.2 Power Supply Unit (PSU)
Mount the PSU to the tunnel wall again using 4 x M6 bolts (customer supply). Mounting hole details are
shown in the illustration Error! Reference ource not found.Figure 4.
Figure 4: PSU – arrangement

CODEL Operation and Maintenance Manual
Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 1003 1 P a g e | 12
4.2 Connection
Wiring hould only be undertaken by a qualified technician.
The following electrical schematic illustrates the connections for the Tunnel Tech 00 Series system.
Figure 5: Electrical Schematic