CODEL TunnelTech 602 User manual

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TunnelTech 602
Illuminance Monitor
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
The TunnelTech 602:...............................................................................................................1
2 Principles of Operation ...................................................................................................................3
3 Specification....................................................................................................................................4
Technical Data:........................................................................................................................4
Construction and Enclosure:...................................................................................................4
Output and Interface: .............................................................................................................4
Compliance and Certification:.................................................................................................5
Cables:.....................................................................................................................................5
Installation Materials:.............................................................................................................5
4 Installation ......................................................................................................................................6
Device dimensions ..................................................................................................................6
Unit Installation.......................................................................................................................7
Cable installation.....................................................................................................................8
Optional 24V DC Power Supply Unit (PSU) Installation ........................................................10
5 Maintenance.................................................................................................................................11
6 mA output.....................................................................................................................................12
7 List of Figures ................................................................................................................................13

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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
Figure 1: TunnelTech 602
The TunnelTech 602:
Is a illuminance photometer, designed for placement within a tunnel to monitor the illuminance level
within, allowing for the tunnel luminaires to be controlled in relation to the light level outside with
the intended purpose of allowing vehicles to enter, pass through and exit the tunnel safely without
impeding the through-flow of traffic.
A signal output from the TunnelTech 602 is fed to a suitable controller to adjust the level of light
intensity inside the road tunnel to the light intensity inside and outside.
Typically, the unit is mounted inside a tunnel and continuously measures the average luminance over
a standard range of 0 –20,000 lux. The luminance data is converted to a 4-20mA output and
transmitted to a host controller to control the luminaries in the tunnel entrance, interior and exit.
The TunnelTech 602 is designed in accordance with Commission Internationale de l´Eclairage, (C.I.E.),
publication 88, 1990 recommendations.
Tunnel lighting monitoring and control is most important at the entrance and exit portals, to ensure
the regulation of luminaire intensity to the correct levels to avoid Tunnel users to be affected by the
black hole effect, whereby they decelerate rapidly due to sudden darkness of the tunnel entrance and
become a hazard to other road users. This is accomplished in conjunction with The TunnelTech 602
Luminance monitor which measures the luminance of the tunnel portal mounted in the access zone,
outside the tunnel. this allowing a control unit or system to alter the light level in accordance with the
luminance outside. Once the user is inside the tunnel and accustomed to the light level change,
luminaires can be reduced in intensity via a “Luminance Reduction Curve” to allow energy to be saved.
Access Zone Interior Zone Exit Zone
Threshold Zone
Transition Zone
Luminance
Figure 2:Tunnel Luminance Curve Graph

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The TunnelTech 602 Illuminance photometer has a 4-20 mA output to export data to tunnel lighting
control systems. The sensor is housed in a rugged glass reinforced polyester enclosure which has an
IP65 rating and has an internal thermostatically controlled heater to prevent fogging of the glass and
allow the device to function at temperatures down to -20°C.
The glass-fibre reinforced polyester enclosure used to house the TunnelTech 602 is tested by an
internationally recognised and certified inspection authority and certified through type approval
testing for use in areas with potentially explosive dust and gas atmospheres, tested to 7 joules.
Calibration against National Physical Laboratory standards is undertaken at the factory and should
not be required in the field.

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2Principles of Operation
The TunnelTech 602 is built around a metal/glass encased reverse-biased silicon diode photocell that
reads the luminance levels of a given area, together with an eye response optical filter 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 output of the photocell is fed into a low noise chopper stabilised amplifier with further stages
provide current limiting, dark current 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 6W 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.

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3Specification
Technical Data:
Measurement Principle:
Silicone Diode Photocell, filtered to human spectral response
Measurement Unit (s):
lx (lux) = cd.sr/m2 (lumen per square meter)
Measurement Range (Typical):
0 to 20,000 lux
Accuracy:
±3 %
Response Time:
Instantaneous
Path Length:
N/A
Ambient Temperature:
-20°C to +50°C
Humidity:
0-100% R.H
Storage Temperature:
-40°C to +75°C
Power Supply:
Nominal Voltage:
Optional as 10 to 35V DC, 110V AC & 240V AC
Temperature Sensor:
Yes.
Construction and Enclosure:
Construction:
Polyester (PET), Glass Fibre Reinforced
Colour/Finish:
Grey (RAL 7001)
Enclosure Rating:
IP66
Weight:
6.0 kg
Outline Dimension:
120 (L) x 249 (H) x 130 (D) (mm)
Output and Interface:
Analogue Outputs:
No.:
1
Type:
4-20 mA

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Compliance and Certification:
EMC:
EN61326-1:2006 & EN50270:2006
Low Voltage:
73/23/EEC (as per datasheet) or 73/23/EEC - Low Voltage and 89/336/EEC -
EMC (as per manual)
Protection:
IP66 (Datasheet) or IP67 (IP69K Optional)
Tunnel Regulation Guidelines:
RABT 2006, RVS 09.02.22 2007 and any others?
Cables:
Power Supply Cable:
110V AC
240V AC
10 to 35V DC
Minimum Specification:
Specified by region
2 Core / 1mm²
Typically Supplied by:
Customer
Analogue Output Cable:
Minimum Specification:
Shielded Belden Type 8771 0.36 mm², or its equivalent
Typically Supplied by:
Customer
Installation Materials:
Installation Bolts
No.:
4
Dimensions:
204 (L) x 82 (H) mm
Bolt Thread Type:
M6
Bolt Length:
60 (mm) or to suit application

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4Installation
CAUTION! Device installation must be performed by specialist technical staff only.
Device dimensions
Figure 3: TunnelTech 602 Dimensions
129.75mm
120mm
248mm
Mounting plate,
supplied by others.
M20 cable gland
for 4-20mA output
M20 cable gland
for 230V AC input

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Unit Installation
Before opening the enclosure, ensure that the power supply Is disconnected.
Mount the TunnelTech 602 to the mounting surface using 4x M6 bolts (by others). Mounting hole
details are shown in
Figure 4 below.
To open the enclosure to access the mounting holes and the power input and signal output
terminals; unscrew the 4 corner screws located on the top or lid of the device using a suitable
screwdriver. Carefully lift off the lid of the enclosure.
Figure 4:mounting dimensions
Once the enclosure lid is removed, the enclosure should be firmly mounted to its intended mounting
surface with 4x M6 bolts (supplied by others) through the pre-made mounting holes detailed in
Figure 4, with a torque of 2.0Nm.
204mm
82mm

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Cable installation
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 armoured Belden Type 8771, or its
equivalent
Insert the electrical and signal cables through the cable glands and make the necessary connections
to the clearly marked POWER and SIGNAL screw terminals, making sure the SIGNAL polarity is
observed.
On 230VAC and 115VAC varieties, ensure to connect the earth cable to the earth terminal
on the POWER connector, with the earth cable being longer than the Live and neutral wires.
In the instance of powering the device via a DC power supply, connect the Positive wire to
the L (live) terminal and the negative wire to the N (neutral).
Figure 5: Electrical Schematic
Figure 6: Electrical Terminal Locations
4-20mA SIGNAL Output Terminal
POWER Input Terminal

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There is no internal fusing in the TunnelTech 602, therefore suitable fusing should be made
in the AC power supply.
The 4 –20mA signal output representing the signal range should be terminated with a resistance of
between 100 ohms and 800 ohms in the control equipment.
The TunnelTech 602 photometer is a stand-alone unit requiring only a mains 220-240V AC 50/60Hz
supply, (or as specified). No auxiliary current supply is necessary.
When electrical connections have been made to power and signal connections, carefully replace the
lid making sure the lid gasket is in place, and re-secure with retaining screws.
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).
On no account should an external current source or voltage be applied to the photometer
signal output connections.

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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 7below.
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 is required.
When cleaning the sensor window, avoid ethyl alcohol, solvents, hydrogenated hydro-carbide,
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.

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6mA output
The output of the TunnelTech 602 is a 4 –20mA current loop. The response from the sensor is
perfectly linear within the measuring range of 0 to 20,000 lux and therefore the Ma output is
delivered accordingly and is updated near constantly.
Figure 8: lux to mA output graph
0
500
1000
1500
2000
2500
45678910 11 12 13 14 15 16 17 18 19 20
Lux to mA output
mA output
Lux
20,000
10,000
5,000
15,000
17,500
12,500
7,500
2,500