CODEL TunnelTech 601 User manual

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TunnelTech 601 Luminance Photometer
Operation and Maintenance Manual
CODEL International Ltd.
Station Building, Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom
t : [phone] f : [phone] e : [email protected] web : www.codel.co.uk

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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]
web : www.codel.co.uk

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Contents
1 System Description .........................................................................................................................1
1.1 The TunnelTech 601:...............................................................................................................1
1.2 Optional accessories ...............................................................................................................1
2 Principles of Operation ...................................................................................................................2
3 Specification....................................................................................................................................3
3.1 Sensor......................................................................................................................................3
3.2 Housing ...................................................................................................................................4
3.3 Certifications...........................................................................................................................4
4 Installation ......................................................................................................................................5
4.1 Device Location.......................................................................................................................5
4.2 Unit Installation.......................................................................................................................6
4.3 Cable installation.....................................................................................................................7
4.4 Optional 24V DC Power Supply Unit (PSU) Installation ..........................................................9
5 Maintenance.................................................................................................................................10
6 mA Output ....................................................................................................................................11
7 List of Figures ................................................................................................................................12

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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

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1System Description
1.1 The TunnelTech 601:
is a Luminance photometer intended for the measurement of luminance at a tunnel’s access zone to
control the level of luminance inside the tunnel’s threshold and transition zones, allowing vehicles to
enter, pass through and exit the enclosed section safely without impeding the through-flow of traffic.
A signal output from the TunnelTech 601 is fed to a suitable controller to adjust the level of light
intensity inside the road tunnel to the light intensity outside,
The TunnelTech 601 Luminance Photometer fully complies with CIE recommendations for road tunnel
lighting control. Typically, the unit is mounted at a tunnel approach road, and aligned to the tunnel’s
entrance portal. It continuously measures the average luminance within a 20° angle over a standard
range of 0 - 6,500 cd/m2. (Other ranges available on request) The luminance data is converted to a 4-
20mA output and transmitted to a host controller for control of luminaries in the tunnel entrance.
1.2 Optional accessories
The TunnelTech 601 is available in 230VAC, 115VAC and 24VDC versions with a range of
potential ancillary accessories available:
•A wash / wipe unit –for automatic cleaning of the enclosure window
•Mounting brackets –specific to the enclosure, with pan and tilt functionalities.
•Fan with air filter –Thermostatically controlled cooling fan activated at 35°C
•24VDC Codel PSU
If the device received is missing any of these options that would be beneficial or is not the right power
specification for the intended application, please contact Codel to arrange a replacement.

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2Principles of Operation
The TunnelTech 601 is built around a metal/glass encased reverse biased silicon diode photocell that
determines the luminance levels of a given area, together with an eye response optical filter with a
20° viewing angle. Optical filters are used to provide measurements of luminance to the required
standard human visible spectral response. The receptor is perfectly linear within the measuring range
and its response to light is virtually instantaneous, sending near constant updated information via a
4-20mA output.
The unit is placed at the safe stopping distance from the tunnel entrance, aimed and centred into the
portal.
The output of the photocell is fed into a low noise chopper stabilised amplifier with further stages
provide current limiting and gain adjustment before being fed into the 4-20mA output current
generator.
Protection against transients is provided for the PCB power input and signal output.
A thermostatically controlled heater is fitted to prevent fogging and correct operation.
Depending on primary power, either an isolation transformer or a DC to DC convertor is fitted to
supply power to the PCB. The cell is practically temperature independent, the correction being less
than +/-1º within 50ºC from the 25ºC calibration temperature.
The TunnelTech 601 complies with CIE recommendations that luminance should be monitored as the
luminance contained within a conical field of view, subtending an angle of 20°and mounted on the
tunnel approach road approximately 120 –200 metres from the portal, depending on the approach
speed of the vehicles and their stopping distance.

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3Specification
3.1 Sensor
Sensor type
Silicon Photocell with eye response filter. 20° viewing
angle
Measurement
cd/m².
Standard measurement range
0-6500 cd/m². (max range 0-10000 cd/m² available on
request)
Calibration
Tracible to British National Physics Laboratory
NPL Ref. 2009080077/594/59.
Operational Temperature
-20°C to 60°C. Dual heater available on request -40°C to
60°C
±1° within 50°C from the 25°C calibration temperature
Electrical connection requirements
230VAC 50/60Hz
115VAC 50/60Hz
24VAC 50/60Hz
24VDC. Range 10 to 35V
Signal output
4 –20mA sourced. External termination 100 –800 ohms
0 –20mA sourced.
0 –5V sourced
Output signal cable
Belden type 8771 (or similar) with conductor resistance of
less than 10 Ω/km is recommended
Power consumption
20VA including internal thermostatically controlled heater
Accuracy
±3%
AC dielectric test
2KV 50Hz for 1 minute
Impulse dielectric test
5KV 1.2/50 microseconds

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3.2 Housing
Material
Extruded aluminium, Epoxypolyester powder paint and
RAL9002 colour stainless steel external screws
Dimensions
L: 493mm W:175mm H:168mm
weight
4.5kg
weatherproofing
Weatherproof standard IP66; Solar protection provided by
extruded aluminium sunshield, Thermostatically
controlled heater element (12 watt consumption). No
separate connection to mains electrical supply
Environment
For indoor and outdoor installation
Cable glands
3 x M16
Housing window material
Glass ((WxH) 94x80mm)
Bracket
Material
Extruded aluminium, Epoxypolyester powder paint and
RAL9002 colour stainless steel external screws
Dimensions
L: 120mm W:120mm H:235mm
Pan
360° lateral angle
Tilt
±120° vertical angle
3.3 Certifications
Electrical safety (CE)
EN60065
Electromagnetic compatibility (CE)
EN50130-4, EN61000-6-3
IP protection degree
EN60529, IP66/IP67 (with cable glands)
EN 60529, IP44 (with double filter for air renewal)
Salty fog resistance
To 1000 hours (ISO9227)
Low voltage
73/23/EEC directive compliant
EAC certification

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4Installation
CAUTION! Device installation must be performed by specialist technical staff only.
4.1 Device Location
The TunnelTech 601 enclosure can be mounted on a purpose-built mounting platform or fastened to
an existing column, wall or other mounting surface in the same manner that any other electrical
surveillance device.
The Tunnel Tech 601 unit should be located such that the following requirements are met:
•Upon various factors e.g. average traffic speed, vehicle driver stopping sight distance road
surface condition etc. A mounting distance of the photometer from the tunnel entrance is
generally accepted at 120-200 metres from the tunnel entrance (see CIE publications No 61
(1984) and No 88 (1990).
•Mounted 4.5 meters above the road surface to avoid traffic obstruction and debris. (see BS
5489 (Part 7), British Dept. of Transport TD 9/81.)
•Pointing and centered towards the tunnel portal.
•Avoid installing in locations where there are or may be obstructions between the light of sight
to the tunnels entrance.
•Ensure there can be electrical power available at the location.
Figure 1: positioning
The stopping distance is the theoretical forward distance required by a driver at a given speed in
order to stop when faced with an unexpected hazard on the carriageway. This takes into account
perception and reaction time as well as road surface conditions.
120-200 meters
4.5 meters
Safe stopping distance
from tunnel entrance

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4.2 Unit Installation
Figure 2: Enclosure Dimensions
The product must be fastened with suitable equipment.
The fastening means must guarantee the mechanical seal
when a force equal to at least 4 times the weight of the
device is applied.
The pan/tilt bracket allows the TunnelTech 601 to be panned
through a 360° lateral angle and tilted vertically through ±120°.
The main device housing is attached to the tilt/pan bracket via two
M6x12mm 10mm hex head bolts and m6 washers, supplied with
the bracket. This is attached to the two threaded mounting holes
on the underside of the enclosure.
The bracket should be firmly mounted to its intended mounting
surface with 4 x M6 bolts (supplied by others) through the pre-
made mounting holes in the base of the bracket.
Figure 3: Bracket dimensions

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4.3 Cable installation
Before starting any installation, ensure that the power supply Is disconnected.
Never under any circumstances make any changes or connection that are not shown in this
manual. Improper use of the appliance can cause serious hazards, risking the safety of
personnel and of the installation.
The signal output cable connection is made via gland to screw terminals, with a conductor resistance
of less than 10 ohms/km. the recommended cable to use is armored Beldon Type 8771 or its
equivalent
To open the enclosure to connect power and
signal output cables, use the Alan keys provided
to undo the socket head screws and grub screws
shown in Figure 4 below.
Once the screws are released, slide the outer
enclosure off the inner section to access the
boards inside.
Feed the intended cables through the supplied
cable glands and once inside the unit connect the
power cable to the J3 terminal on the enclosure’s
Power Distribution and Heater Control PCB.
Depending on the voltage requirements of the version supplied a 24VDC PSU may be required. In this
scenario, connect the +24VDC out to L on the J3 terminal and 0V to N.
Figure 5: Power Distribution and Heater Control PCB
On 230VAC and 115VAC varieties, ensure to connect a power earth cable to the earth
terminal on the J3 connector of the Power Distribution Board.
The earth cable should be about 10mm longer than the other two, so that it will not be
disconnected accidentally if pulled.
Connector
Function
J1
Camera power supply (Vout)
J2
Heater power supply (Vout)
J3
Board Power supply (Vin)
J4
Auxiliary output (Vout) to Phot
J5
Power supply connector/jumper
J6
Fan power supply (Vout)
Figure 4: enclosure disassembly

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Figure 6: Luminance Amp and Current Driver PCB
CAUTION! The type of cable used must be compatible with the planned use and comply
with the national regulations in force on electrical installation.
connect the signal output cable to the TB2 terminal (marked Sig) on the Luminance Amplifier and
Current Driver PCB, paying attention to the + and –orientation on the silkscreen of the board.
After all cables are connected to the required terminals and the glands tightened and secured, close
the enclosure and re-tighten the socket head bolts and grub screws. Ensure to reconnecting the
outer case earth jumper cable to the power distribution PCB, if this was removed during the opening
of the enclosure for the cable installation.
CAUTION! The electrical system to which the unit is connected must be equipped with a
15A max automatic bipolar circuit breaker. The maximum distance between the circuit
breaker contacts must be provided with protection against fault current towards the
ground (differential) and the overcurrent (magnetothermal).
It is intended for the signal output to be terminated in the display/controlling equipment by
using a resistance value between 1000hms and 800 ohms.
On no account should an external current source or voltage be applied to the photometer
signal output connections.

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4.4 Optional 24V DC Power Supply Unit (PSU) Installation
Mount the PSU to the mounting surface using 4 M6 bolts (by others). Mounting hole details are
shown in Figure 7 below
Figure 7: Optional PSU mounting Arrangement
Make sure the PSU enclosure is earthed with a grounding strap during installation using
the earthing bolt.

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5Maintenance
Recalibration checks: The silicone receptor is extremely stable over a long period. Recalibration
checks are not normally necessary within ten-year periods.
Maintenance: Minimal. Occasional cleaning of the viewing window. (Not necessary if automatic
Wash/Wipe unit is fitted, available upon request).
When cleaning the sensor window, avoid ethyl alcohol, solvents, hydrogenated hydrocarbide,
strong acids and alkalis. Such products may irreparably damage the viewing window surface
It is recommended using a soft cloth with neutral soap diluted with water or specific products to
clean the glass lens.
If the optional washer wiper unit is installed on the device, then the screen cleaning procedure is not
necessary, although the refilling of the reservoir will become necessary.

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6mA Output
the output of the TunnelTech 601 is a standard 4- 20mA current loop. The response from the sensor
is perfectly linear within the calibrated range of 0 to 6500 cd/m² and therefore the mA output is
delivered accordingly and is updated near constantly.
Each TunnelTech 601 is tested at several points against a traceable standard unit.
Figure 8: cd/m2 to mA output (4-20) graph
Although the standard TunnelTech 601 has a measurement range of 6500 cd/m2, other calibrated
ranges as per customer requirements, as well as a 0 - 20mA output option are available upon
request.
1300
2600
3900
5200
6500
650
1950
3250
4550
5850

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7List of Figures
Figure 1: positioning ...............................................................................................................................5
Figure 2: Enclosure Dimensions..............................................................................................................6
Figure 3: Bracket dimensions..................................................................................................................6
Figure 4: enclosure disassembly .............................................................................................................7
Figure 5: Power Distribution and Heater Control PCB............................................................................7
Figure 6: Luminance Amp and Current Driver PCB.................................................................................8
Figure 7: Optional PSU mounting Arrangement.....................................................................................9
Figure 8: cd/m2 to mA output (4-20) graph .........................................................................................11