Forbes Marshall CODEL TunnelTech 500 Series Operating instructions

Section 1
System Description
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 1
TunnelTech 500/700 Series
Operating and Maintenance Manual
Tunnel Atmosphere Monitoring System
(CO/NO/NO2/Vis)
CODEL International Ltd.
Unit 4, Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom
t : [phone] f : [phone] e : [email protected] web : www.codel.co.uk

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TunnelTech500/700
Operating-and-Maintenance-Manual

Section 1
System Description
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 3
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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TunnelTech500/700
Operating-and-Maintenance-Manual

Section 1
System Description
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 5
Contents
1SYSTEM DESCRIPTION ...............................................................................................9
THE TUNNELTECH 500/700 SERIES ................................................................................9
TUNNELTECH 500 -CO, NO AND NO2 AIR QUALITY MONITOR ............................10
TUNNELTECH 700 -CO, NO, NO2,AND VISIBILITY AIR QUALITY MONITOR............11
TUNNELTECH 500 VERSIONS....................................................................................13
1.4.1 TunnelTech 500 Series: (Aluminium) ...........................................................13
1.4.2 TunnelTech 510 Series: (Stainless Steel)......................................................13
TUNNELTECH 700 VERSIONS..........................................................................................14
1.5.1 TunnelTech 700 Series: (Aluminium)..........................................................14
1.5.2 TunnelTech 710 Series: (Stainless-Steel) .....................................................14
POWER SUPPLY ...............................................................................................................15
2PRINCIPLES OF OPERATION...................................................................................16
ELECTRO-CHEMICAL CELL:.............................................................................................16
2.1.1 E-Cell Calibration:.............................................................................................16
TECHNICAL DATA: ......................................................................................................17
3SPECIFICATION..........................................................................................................17
CONSTRUCTION AND ENCLOSURE.................................................................................18
OUTPUT AND INTERFACE (OPTIONAL):.....................................................................18
OPTIONAL ITEMS:.......................................................................................................19
COMPLIANCE AND CERTIFICATION ...........................................................................19
CABLES:(RECOMMENDED MINIMUM SPECIFICATION) ...........................................20
TUNNELTECH 500 INSTALLATION MATERIAL..........................................................20
TUNNELTECH 700 INSTALLATION MATERIAL...........................................................21
4INSTALLATION.......................................................................................................... 22
DIMENSIONS &MOUNTING DETAILS ......................................................................22
4.1.1 tunnelTech 500 (Aluminium) ........................................................................22
4.1.2 Mounting Details (Stainless steel)................................................................ 23
4.1.3 TunnelTech 700 series: ................................................................................... 24
4.1.4 TunnelTech 708: (Vis only) .............................................................................25
4.1.5 TunnelTech 710 series: (Stainless Steel) ..................................................... 26
BRACKET MOUNTING DETAILS:................................................................................27
POWER SUPPLY UNIT (OPTIONAL)MOUNTING DETAILS .......................................29
CONNECTIONS..........................................................................................................30
4.4.1 TT500................................................................................................................... 30
4.4.2 TT700....................................................................................................................31
4.4.3 Power Connection:........................................................................................... 32
4.4.4 RS485 Connection:........................................................................................... 32
4.4.5 PCB Identification & Connections - Lid:..................................................... 33
4.4.6 PCB Identification & Connections - Base: ................................................. 34
5COMMISSIONING..................................................................................................... 35
POWER UP......................................................................................................................35

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TunnelTech500/700
Operating-and-Maintenance-Manual
TIME AND DATE ........................................................................................................35
VISIBILITY COMMISSIONING (TT700 ONLY) ............................................................37
5.3.1 Visibility Module Communication: .............................................................. 37
5.3.2 Transmissometer Alignment:........................................................................ 38
5.3.3 Final Alignment: ............................................................................................... 40
5.3.4 Transmissometer Detector Level Setup: ................................................... 42
5.3.5 Visibility Zero Calibration:.............................................................................. 44
E-CELL COMMISSIONING .........................................................................................45
5.4.1 E-Cell Module Communication:................................................................... 45
5.4.2 Detector Levels:................................................................................................. 46
5.4.3 Maintenance Due: ........................................................................................... 47
MAOUTPUT SETUP...................................................................................................48
5.6.1 Species Configuration: .................................................................................... 48
5.6.2 mA Zero Value: ................................................................................................ 48
5.6.3 mA Span Value: ............................................................................................... 49
5.6.4 DAC Zero / Span: ............................................................................................ 50
RELAY OUTPUT SETUP ..............................................................................................53
5.7.1 Relay Trigger Measurand: ............................................................................. 53
5.7.2 Relay Direction:..................................................................................................55
5.7.3 Relay Alarm Level:.............................................................................................55
6MAINTENANCE......................................................................................................... 56
VISIBILITY (TT700 ONLY)...............................................................................................56
6.1.1 Mechanical Check:........................................................................................... 56
6.1.2 Physical Alignment: ..........................................................................................57
ELECTROCHEMICAL CELL ..........................................................................................59
6.2.1 Mechanical Check:........................................................................................... 59
6.2.2 Span Check / Zero Calibration:.................................................................... 59
6.2.3 Zero Calibration: .............................................................................................. 62
6.2.4 E-Cell Replacement: ........................................................................................ 63
6.2.5 Replacement E-Cell PCBs: ............................................................................. 66
SPARE PARTS.............................................................................................................66
6.3.1 Optional Components: ...................................................................................66
7DATA COMMUNICATION ...................................................................................... 67
HARDWARE CONFIGURATION .......................................................................................67
7.1.1 System:................................................................................................................ 67
8TABLE OF FIGURES................................................................................................... 68
9APPENDIX 1: RS485 COMMUNICATIONS ........................................................... 69
MODBUS RTU COMMUNICATION..............................................................................70
9.1.1 Host Request Frame:....................................................................................... 70
9.1.2 Slave Response: (from Codel Modbus TunnelTech 700) ....................... 70
KEY MODBUS DATA REGISTER LOCATIONS..............................................................71
9.2.1 Configuring RS485 Protocol & Addressing.................................................72
10 APPENDIX 2 –DATA VALID & CUSTOM RELAY MEASURANDS ................... 74
10.1.1 Data valid........................................................................................................... 74

Section 1
System Description
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 7
10.1.2 Custom ...........................................................................................................75
11 APPENDIX 3 –INTERNAL ADDRESS NUMBERS................................................. 76
12 APPENDIX 4 –OPTIONAL HEATED MIRRORS ............................................... 77
ARRANGEMENT AND CONNECTIONS ....................................................................... 77
12.1.1 Arrangement:.....................................................................................................77
12.1.2 Connections:.......................................................................................................77
13 APPENDIX 5 –MEMORY MAP............................................................................... 80
MEMORY OVERVIEW.................................................................................................80
DISPLAY RAM............................................................................................................81
DISPLAY EEPROM ...................................................................................................92
VIS EEPROM........................................................................................................... 110
E-CELL RAM............................................................................................................ 119
E-CELL EEPROM....................................................................................................127
MARAM..................................................................................................................137
MAEEPROM......................................................................................................... 139
MA2 RAM............................................................................................................... 147
MA2 EEPROM....................................................................................................... 149
COMMANDS............................................................................................................ 155

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TunnelTech500/700
Operating-and-Maintenance-Manual
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

Section 1
System Description
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 9
1System Description
The TunnelTech 700 setup shown in figure 1 uses visible light to measure visibility
and electrochemical cells to measure gases such as CO, NO, NO2.
The TunnelTech 700 consists of a transceiver that projects visible light beam to a
reflector unit mounted 3m away. A high-Intensity modulated LED is used for the
visible light source. Optical visibility is measured by a silicon photo-detector that
determines the attenuation of the light beam, along the instrument sight path, due
to the particulates in the tunnel atmosphere.
CO, NO and NO2are 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 RS485
interface allows communication directly with the TunnelTech 700 sensors.
The TunnelTech 500/700 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
Visibility (TunnelTech 700 only)
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.

Page: 10
TunnelTech500/700
Operating-and-Maintenance-Manual
TunnelTech 500 - CO, NO and
NO2 Air Quality Monitor
The monitoring stations provide all required measurements and outputs at each
monitoring location within the tunnel.
The TunnelTech 500 setup shown in figure 1 uses visible light to measure visibility
and electrochemical cells to measure gases such as CO, NO, NO2.
CO, NO and NO2are 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 RS485
interface allows communication directly with the TunnelTech 500 sensors.
Figure 1: TunnelTech 500
Monitor Stations
Mains Supply
24V DC
Modbus,
current &
analogue
outputs

Section 1
System Description
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 11
TunnelTech 700 - CO, NO,
NO2, and Visibility Air Quality
Monitor
The monitoring stations provide all required measurements and outputs at each
monitoring location within the tunnel.
The TunnelTech 700 setup shown in figure 1 uses visible light to measure visibility
and electrochemical cells to measure gases such as CO, NO, NO2.
The TunnelTech 700 consists of a transceiver that projects visible light beam to a
reflector unit mounted 3m away. A high-Intensity modulated LED is used for the
visible light source. Optical visibility is measured by a silicon photo-detector that
determines the attenuation of the light beam, along the instrument sight path, due
to the particulates in the tunnel atmosphere.
CO, NO and NO2are measured using electrochemical cell technology. Once the
zero level of the cell is set and recorded in the instrument memory, the cell output
Figure 2: TunnelTech
700 Monitor Stations
Mains Supply
24V DC
Modbus,
current &
analogue
outputs
Mirror
Transceiver
3m

Page: 12
TunnelTech500/700
Operating-and-Maintenance-Manual
is linear and proportional to the ppm or ppb reading. A serial data link via an RS485
interface allows communication directly with the TunnelTech 700 sensors.
All varieties of TunnelTech 700 and 710 are mounted using the same method, and
both aluminium and stainless-steel brackets are made to the same dimensions. For
mounting details, refer to sections 4.2 and 4.1.
Figure 3: TunnelTech 710
Figure 4: TunnelTech 700
Modbus,
current &
analogue
outputs
Mirror
Transceiver
3m
Mains Supply
24V DC
Modbus,
current &
analogue
outputs
Mirror
Transceiver
3m

Section 1
System Description
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 13
TunnelTech 500 Versions
Model No.
Gas
PCB Boards
CO
NO
NO²
Ma
Display
511
✓
✓
✓
✓
511 mA
✓
✓
✓
2
✓
512
✓
✓
✓
512 mA
✓
✓
1
✓
513
✓
✓
513 mA
✓
1
✓
514
✓
✓
514 mA
✓
1
✓
515
✓
✓
515 mA
✓
1
✓
516
✓
✓
✓
516 mA
✓
✓
1
✓
517
✓
✓
✓
517 mA
✓
✓
1
✓
1.4.1 TunnelTech 500 Series:
(Aluminium)
Model No.
Gas
PCB Boards
CO
NO
NO²
Ma
Display
501
✓
✓
✓
✓
501mA
✓
✓
✓
2
✓
502
✓
✓
✓
502mA
✓
✓
1
✓
503
✓
✓
503mA
✓
1
✓
504
✓
✓
504mA
✓
1
✓
505
✓
✓
505mA
✓
1
✓
506
✓
✓
✓
506mA
✓
✓
1
✓
507
✓
✓
✓
507mA
✓
✓
1
✓
1.4.2 TunnelTech 510 Series:
(Stainless Steel)

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TunnelTech500/700
Operating-and-Maintenance-Manual
TunnelTech 700 versions
1.5.1 TunnelTech 700 Series:
(Aluminium)
Model No.
Gas
PCB Boards
CO
NO
NO²
Vis
Ma
Display
701
✓
✓
✓
✓
✓
701mA
✓
✓
✓
✓
2
✓
702
✓
✓
✓
✓
702mA
✓
✓
✓
2
✓
703
✓
✓
✓
703mA
✓
✓
1
✓
704
✓
✓
✓
704mA
✓
✓
1
✓
705
✓
✓
✓
705mA
✓
✓
1
✓
706
✓
✓
✓
✓
706mA
✓
✓
✓
2
✓
707
✓
✓
✓
✓
707mA
✓
✓
✓
2
✓
708
✓
✓
708mA
✓
1
✓
Model No.
Gas
PCB Boards
CO
NO
NO²
Vis
Ma
Display
711
✓
✓
✓
✓
✓
711 mA
✓
✓
✓
✓
2
✓
712
✓
✓
✓
✓
712 mA
✓
✓
✓
2
✓
713
✓
✓
✓
713 mA
✓
✓
1
✓
714
✓
✓
✓
714 mA
✓
✓
1
✓
715
✓
✓
✓
715 mA
✓
✓
1
✓
716
✓
✓
✓
✓
716 mA
✓
✓
✓
2
✓
717
✓
✓
✓
✓
717 mA
✓
✓
✓
2
✓
718
✓
✓
718 mA
✓
1
✓
1.5.2 TunnelTech 710 Series:
(Stainless-Steel)

Section 1
System Description
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 15
Power Supply
A PSU is required to convert the mains (90-263V AC) supply to the 24V DC
required to power the TunnelTech 700.
Figure 5: Codel 24V DC Power
Supply Unit
Mains Input
Connection
24V DC outputs
24V DC
Earthing bolt

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TunnelTech500/700
Operating-and-Maintenance-Manual
2Principles of Operation
Electro-Chemical Cell:
In order to measure the level of gas (CO/NO/NO2), the Tunnel Tech 700 uses an
electro chemical cell to convert the gas in to readable data. The gas diffuses into
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 concentration and the detector level is derived from the
incoming voltage and subsequently a gas measurement.
The instrument should be calibrated when measured gases are zero. this is
achieved by purging the instrument with a non-cross sensitive gas, such as
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. For further E-Cell calibration
details, see section 6.2.
2.1.1 E-Cell Calibration:

Section 3
Specification
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 17
3Specification
Technical data:
VIS (TT700 only)
E-Cell
Measurement type:
Visibility
CO
NO
NO2
Measurement principle:
Optical
Transmissometry
Electrochemical Cell
Measurement units:
% or K factor (m-1)
ppm
ppm
ppb
Nominal Measurement range
(typical):
0 to 100 %
0 to 800 ppm
0 to 160 ppm
0 to 10000 ppb
Measurement range (typical):
0 to 8.6 % or 0 to
0.015 K
1 to 300 ppm
1 to 30 ppm
1000 to 5000ppb
Accuracy:
±0.1 % or 0.0002 K
±2 ppm
±2 ppm
±100 ppb
Resolution:
±0.01 % or
±0.0001 K
0.1 ppm
0.1 ppm
1 ppb
Response time:
60 seconds
30 seconds
30 seconds
30 seconds
Averaging time:
30 seconds to 3 minutes (Configurable)
Path length:
6m Folded Beam
N/A
Humidity:
0 - 95% RH
10-90% R.H
Storage temp:
-40 to 75 C
+5°C to +25°C
Operating temperature:
'-20°C to +55°C
-20°C to +50°C (Cell Temp)
Nominal power supply:
24V DC
Nominal power consumption:
30W
Interface:
16x2 Display + Keypad
Temperature sensor:
On board

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TunnelTech500/700
Operating-and-Maintenance-Manual
Construction and Enclosure
Aluminium
Stainless Steel (Optional)
Construction:
Epoxy Coated Die-Cast Aluminium
Stainless Steel 316L
or Stainless Steel 316Ti
Colour/Finish:
Black (RAL 9005 - Jet Black) (Aluminium)
Silver/ stainless steel
(220-240 grit dull polished)
Enclosure Rating:
Designed to IP66 (IP69K Optional)
Designed to IP66
Weight:
4.5 kg (15 Kg with brackets)
5 kg (30 Kg with brackets)
Outline Dimension
200 (L) x 230 (H) x 110 (D) (mm)
200 (L) x 250 (H) x 150 (D) (mm)
Output and Interface (Optional):
Communication Port
No.:
1
Type:
RS485 ModBUS RTU
Analogue Outputs (mA)
No.:
2 or 4
Type:
4-20 mA
Max. Load:
500Ω
Other:
Isolated, fully configurable for CO, NO, NO2 and Visibility
Contact Outputs (Relay)
No.:
2 or 4
Type:
SPCO
Max. Load:
500mA @ 60V DC
Other:
Configurable as alarm contacts

Section 3
Specification
Issue: A Revision: 10 Date: 10/01/22 Ref: 100575
Page: 19
Optional Items:
24V DC Power Supply
Input:
110 - 240V AC @ 100W Max., 50/60 Hz
Output:
24V DC @ 60W
Dimension:
200 (L) x 230 (H) x 110 (D) (mm)
Colour:
Black (RAL9005 - Jet Black)
Construction:
Die-cast Aluminium
Enclosure Rating:
IP66
Weight:
4.0 kg
Compliance and Certification
EMC:
Designed to 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
Tunnel Regulation Guidelines:
RABT 2006, RVS 09.02.22 2007

Page: 20
TunnelTech500/700
Operating-and-Maintenance-Manual
Cables: (Recommended Minimum Specification)
Power Supply Cable:
Shielding:
Shielded to enclosure
Cores / Wire Diameter:
2 Core / 1mm²
Typically Supplied by:
Customer
RS485 ModBUS Cable:
Shielding:
Shielded away from enclosure
Cores / Wire Diameter:
2 Core / 0.5mm²
Typically Supplied by:
Customer
Analogue Output Cable:
Shielding:
Shielded to enclosure
Cores / Wire Diameter:
4 Core / 1mm²
Typically Supplied by:
Customer
Contact Output Cable:
Shielding:
Shielded to enclosure
Cores / Wire Diameter:
4 Core / 1mm²
Typically Supplied by:
Customer
TunnelTech 500 Installation Material
Installation Bolts:
Sensor Body:
No.:
4
Bolt Thread Type:
M6
Bolt Length:
60 (mm) or to suit application
24V Power Supply:
No.:
4
Bolt Thread Type:
M6
Bolt Length:
60 (mm) or to suit application