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CODEL Tunnel Tech 700 Series Technical Manual

Tunnel atmosphere monitoring system (co/no/no2/vis)
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Tunnel Atmosphere Monitoring System
Station Building, Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom
t : +44 (0) 1629 814 351
Issue : A
TECHNICAL MANUAL
Tunnel Tech 700 Series
Tunnel Tech 701 - CO/NO/NO²/VIS
Tunnel Tech 702 - CO/VIS/VIS
Tunnel Tech 703 - CO/VIS
Tunnel Tech 704 – NO/VIS
Tunnel Tech 705 - NO²/VIS
Tunnel Tech 706 – CO/NO²/VIS
Tunnel Tech 707 – NO/NO²/VIS
Tunnel Tech 708 - VIS Only
(CO/NO/NO²/Vis)
CODEL International Ltd.
f : +44 (0) 8700 566 307
Rev. : 0
e : codel@codel.co.uk
Date : 25/04/17
web : www.codel.co.uk
Ref. : 100303

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  • Page 1 TECHNICAL MANUAL Tunnel Tech 700 Series Tunnel Tech 701 - CO/NO/NO²/VIS Tunnel Tech 702 - CO/VIS/VIS Tunnel Tech 703 - CO/VIS Tunnel Tech 704 – NO/VIS Tunnel Tech 705 - NO²/VIS Tunnel Tech 706 – CO/NO²/VIS Tunnel Tech 707 – NO/NO²/VIS...
  • Page 2 Issue : A Rev. : 0 Date : 25/04/17 Ref. : 100303...
  • Page 3 CODEL Issue : A Rev. : 0 Date : 25/04/17 Ref. : 100303...
  • Page 4 CODEL 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.
  • Page 5 CODEL Issue : A Rev. : 0 Date : 25/04/17 Ref. : 100303...

  • Page 7: Table Of Contents

    CODEL Technical Manual Contents 1. System Description 1.1. The Tunnel Tech 700 Series Concept 1.2. CO, NO, NO², and Visibility Air Quality Monitor 1.3. Power Supply Unit (PSU) Principles of Operation 2.1. Air Quality Monitor (AQM) 2.1.1. VisibilityMeasurement 2.1.2. CO. NO & NO2Measurement 3.
  • Page 8 CODEL Technical Manual 7.2. Address Numbers 8. List of Figures Appendix 1 : MODBUS Communication & RS485 Connection Appendix 2 : Optional Tunnel Display Unit (TDU) Appendix 3: Optional Heated Mirrors arrangement & connection Issue : A Rev. : 0 Date : 25/04/17 Ref.
  • Page 9 CODEL Technical 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.
  • Page 10 CODEL Technical Manual Issue : A Rev. : 0 Date : 25/04/17 Ref. : 100303...

  • Page 11: System Description

    1. System Description 1.1. The Tunnel Tech 700 Series Concept Tunnel Tech 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:...

  • Page 12: Co, No, No², And Visibility Air Quality Monitor

    CO/NO/NO²/VIS Quality Monitor Figure 1 : Tunnel Tech 700 Series - Monitoring Station 1.2. CO, NO, NO², and Visibility Air Quality Monitor The Air Quality Monitor (AQM), shown in Figure 2, uses visible light channels to measure visibility and electrochemical cells. The AQM consists of a transceiver that projects visible beams to a reflector unit mounted 3m away.

  • Page 13: Power Supply Unit (Psu)

    The PSU is required to convert the mains (90-263V AC) supply to the 12V or 24V DC required to power the AQM. mains input 24V DC 12V DC connections DC outputs DC outputs Figure 3 : Tunnel Tech 700 Series - power supply units 12V DC & 24V DC...

  • Page 14: Principles Of Operation

    CODEL Technical Manual Principles of Operation 2.1. Air Quality Monitor (AQM) 2.1.1. Visibility Measurement 2.1.1.1.Transmissometry Principles Visibility Dimming Coefficient (abbreviated to Dim K or Vis K) Fine particles suspended in the atmosphere will scatter a beam of light so that the intensity of the beam reduces as it passes through the air.
  • Page 15 CODEL Technical Manual 2.1.1.2. LED Control Operation of the emitting LED is controlled by the on-board processor. The LED is pulsed periodically as shown in figure 4.These very brief duration pulses enable the instrument to operate without interference from other light sources within the tunnel.

  • Page 16: Co. No & No2Measurement

    CODEL Technical Manual In order to calculate the opacity from the data collected by the detectors, a Y value has to be established. This is done by using the Vis TX and Vis RX data, along with the Set Cal as shown in section 2.1.1.5;...

  • Page 17: Specifications

    CODEL Technical Manual 3. Specifications 3.1. General Construction corrosion resistant epoxy coated aluminium housings sealed to IP66 (AQM & PSU) optional 316 stainless steel and 316 stainless steel TI for heads and brackets Electro-magnetic immunity shielded to comply with 73/23/EEC - low voltage and 89/336/EEC-EMC...

  • Page 18: Rs485 Interface

    NO - ±2ppm or 2% span NO² - ±100ppb Power 24V DC, 24VA (obtained from PSU) Communications Serial RS485 interface via plug and socket for diagnostics, RS485 Modbus, or Codel Protocol Outputs (Optional) analogue - 2 x 4-20mA, 200V Common max.

  • Page 19: Installation

    CODEL Technical Manual 4. Installation Be sure to observe all necessary safety precautions at all times during installation. All cable gland entry holes are drilled and tapped M20 x 1.5 and are fitted with blanking plugs. Cable glands are to be supplied by the customer according to the cables used during installation.

  • Page 20: Connections

    CODEL Technical Manual Figure 6 : PSU – arrangement 4.2. Connections Wiring should only be undertaken by a qualified technician. The following electrical schematic illustrates the connections for the Tunnel Tech 700 Series system.
  • Page 21 CODEL Technical Manual Figure 7 : Electrical Schematic...
  • Page 22 CODEL Technical Manual Power Connection: Place 24V screened cable through the gland and connect to CON1 24V power input as described below Figure 8: Power Connection RS485 Connection Figure 9: RS485 Connection...
  • Page 23 CODEL Technical Manual Control/Display PCB Power Electrochemical Cell Communications...
  • Page 24 CODEL Technical Manual Visibility PCB Top; mA/RLY 4&5 Ma Output PCB’S Bottom; mA/RLY 1&2...

  • Page 25: Commissioning

    After checking all the cable connections against the connection schedule, switch on the mains power and wait for power-up sequence to complete and Data validity LED (green) to come on. When powered on, the display unit will come on displaying CODEL – FM (manufacturer’s name) and TunnelTech 700 (instrument’s name).

  • Page 26: Alignment

    CODEL Technical Manual 5.2.1.5. When completely covered, the Vis DRx reading should drop close to 0 after a few moments. This reading indicates that the display module and the visibility module are communicating and operating correctly. VIS DRx: 5.2.1.6. When communication has been established, the next stage of commissioning is Alignment.
  • Page 27 CODEL Technical Manual 5.2.2.2. Use the key to reach Vis Diag, and press to access. 3. DIAGNOSTICS 3.5. VIS Diag 5.2.2.3. Use the to reach Vis DRx, and press to access. 5.2.2.4. Vis DRx: Observe DRx Smoothed value while adjusting the optical alignment of the instrument until this value has reached a plateau.

  • Page 28: Calibration Vis

    CODEL Technical Manual 5.2.4. Calibration Vis To begin calibration of VIS, follow the steps below on the display unit. Note: When ‘Enter to CAL’ has been selected, allow 5-10 minutes for calibration to complete. 5.2.4.1. Press to return to the main display.

  • Page 29: Electrochemical Cell Commissioning

    CODEL Technical Manual 5.3. E-Cell commissioning 5.3.1. E-Cell module communication To ensure that there is a working communication between the display unit and the electrochemical cell module, follow the steps below using the display. 5.3.1.1. Press to return to the main display.
  • Page 30 CODEL Technical Manual 5.3.2.1. Press to return to the main display. 1. Meas - 09:24:29 CO: 21 ppm From the main display press to reach Diagnostics. Press to access Diagnostic data. 3. DIAGNOSTICS 5.3.2.2. Use the key to reach E-C CH1 Diag, and press to access.

  • Page 31: Electrochemical Cell Calibration

    CODEL Technical Manual 5.3.3. Electrochemical Cell Calibration To begin zero calibration of E-Cell, follow the steps below on the display unit. Note: When ‘Enter to CAL’ 10 has been selected, allow 3 minutes for calibration to complete. to return to the main display.

  • Page 32: Maintenance

    CODEL Technical Manual 6. Maintenance The Tunnel Tech 700 Series system is designed for low maintenance. The sensors utilise the latest microprocessor technology. The AQM sensor uses an infrared source that has a life expectancy of over 3 years. 6.1. Routine Maintenance 6.1.1.

  • Page 33: Electrochemical Cell Calibration

    CODEL Technical Manual 6.1.1.6. If the detector levels are not within the range of 10000 +/-2000, move on to physical alignment. 6.1.1.7. Alignment. 6.1.1.8. After physically altering the alignment as shown in the previous section, run a zero Cal to calibrate the system.

  • Page 34: Electrochemical Cell Replacement

    6.1.3. Electrochemical Cell replacement Every 18 months it is required to replace the electrochemical cell. The replacement cells will be supplied from CODEL pre-calibrated complete with card. 6.1.3.1. To remove the electrochemical cell, open the TT700 casing and locate the E-Cell.
  • Page 35 CODEL Technical Manual Electrochemical Cell 6.2.1.2. Remove ribbon cable. 6.2.1.3. Remove the four screws from the four corners of the E-Cell. Ensure that these are kept safe. 6.2.1.4. Slowly remove the E-Cell from the Unit. 6.2.1.5. Insert the new E-Cell in to the unit and screw back in to place.

  • Page 36: Part Numbers & Replacement List

    CODEL Technical Manual 6.1.4. Part Numbers and List of Replacement CO – 991.606 CO, NO – 991.604 CO, NO, NO2 – 991.598 NO – 991.608 NO, NO2 – 991.614 NO2 – 991.610 6.1.5. Optional Parts Vis Check Filters: 1% - 991.528A...
  • Page 37 CODEL Technical Manual Alignment Laser: Please Call CODEL mA/Relay Card: 803.604D...

  • Page 38: Data Communication

    The PSU supplies power to the AQM. The current and relay outputs of the AQM communicate measurement data to the tunnels' DCS system. Figure 10 : Tunnel Tech 700 Series - system configuration 7.1.2. Processor Architecture Figure shows the system processor architecture.
  • Page 39 CODEL Technical Manual Each sensor possesses two processors organised as a master/slave pair. In each case, the master processor handles all communications to and from the device, while the slave processor concentrates on the measurement of the parameters necessary for the monitoring process. This enables all sensor processing to be made without interruption by external communications.
  • Page 40 Figure 1 : Tunnel Tech 700 Series - network Figure 2 : Tunnel Tech 700 Series - CO/NO/NO2Vis air quality monitor Figure 3 : Tunnel Tech 700 Series - power supply units 12V DC & 24V DC Figure 4 : LED Pulse Graph...
  • Page 41 TRx lines + and -. Optional Extra Diagnostic & Commissioning tool Illustrated is the serial USB-RS485 interface (complete with pc software drivers & cable) supplied by CODEL for temporary connection to the AQM during commissioning and diagnostic communications.
  • Page 42 Using standard MODBUS protocol function 03 allows a host to obtain the contents of one or more holding registers in the CODEL MODBUS TT Air Quality Monitor (AQM). The request frame from the host (typically a DCS or SCADA) defines the relative address of the first holding register followed by the total number of consecutive registers to be read.
  • Page 43 CODEL Technical Manual Note that this is Standard Modbus protocol NOT Modbus Plus protocol. Reference: AEG Modicon Modbus Protocol Reference Guide PI-MBUS-300 Rev.D. Modbus register location  0070h NO ppm data 0001h = 1ppm, 001Eh = 30ppm 0071h CO ppm data 0001h = 1ppm, 0190h = 400ppm 0072h Opacity data 0001h = 0.01%, 0064h = 1.00%...
  • Page 44 CODEL Technical Manual Data Register Locations at CODEL Tunnel Tech 700 Series AQM for Interrogation using Standard MODBUS Register Format Customer Specific Details Location Details Data Units Typical Range Value 0070 NOppm XXXX 1ppm 0-30ppm XXXX 0071 COppm XXXX 1ppm...
  • Page 45 CODEL Technical Manual Appendix 2 – Optional Heated Mirrors arrangement & connection The mounting arrangement for the heated mirror assembly is shown below. CO/NO/NO²/VIS Air Quality Monitor The heated mirror assembly is wired directly into the 12V or 24V DC power supply as illustrated...
  • Page 46 CODEL Technical Manual Appendix 3 – Menu Interface User Menu Table of Contents 1. Introduction 2. Keypad 3. Welcome Screen 4. Main Menu 5. Meas 5.1. Select Channel 6. Parameters 6.1. ID 6.2. Comms 7. Diagnostics 7.1. Running Mode 7.2. E-C CH1 Diag 7.3.

  • Page 47: Introduction

    -To exit to main screen -To Select/Apply/Exit -To Scroll up/Increment -To Scroll Down/Decrement 3. Welcome Screen: The welcome screen displays Codel-FM (manufacturer’s name) and TunnelTech 700 (instrument’s name). CODEL – FM TunnelTech 700 Few seconds later the measurement screen appears.

  • Page 48: Select Channel

    CODEL Technical Manual 5.1. Select Channel: Allows user to select a channel to be displayed. The following are the submenus.  Select Unit  E-Cell CH1  E-Cell CH2  E-Cell CH3  Vis %  Vis_k  Vis_m  Multi-gas ...

  • Page 49: Parameters

    CODEL Technical Manual 5.5. Vis_k: Displays Vis_k data.  Use to scroll through to Vis_k and press to select Vis_k. display returns measurement screen displaying Vis_k measurement. 1. Meas – 09:38:14 Select Channel Vis_k Vis: 0.0010k 5.6. Vis_m: Displays Vis_meter data.
  • Page 50  Soft-Build  Target Board 6.1.1. Manufacturer: Displays manufacturer information.  Press to access manufacturer information. Manufacturer: CODEL - FM 6.1.2. Equipment: Displays equipment’s name.  Use to scroll through to Equipment. Equipment: TT700-DISPLAY M 6.1.3. Soft-Version: Displays software version used in the instrument.

  • Page 51: Comms

    CODEL Technical Manual 10 is the date 02 is the month 16 is the year 6.1.5. Target Board: Displays the Circuit Board information that Software Version on the instrument supports.  Use to scroll through to Target Board. Target Board: 803441A Example of target board number format in screen shot “803441A”...

  • Page 52: Diagnostics

    CODEL Technical Manual Comms Address: 6.2.4. Press to exit from Comms submenu. 6.3. Exit: Allows user to exit to main menu.  Use to scroll through to Exit and press to exit to main menu. 2. PARAMETERS 2. Parameters Exit 7.
  • Page 53 CODEL Technical Manual 7.2. E-C CH1 Diag: Displays E-C CH1 information at different data processing stages. The following are the submenus.  E-C CH1 Diag  Dcal  DRx  Z  Raw  Smt  Use to scroll through to E-C CH1 Diag.
  • Page 54 CODEL Technical Manual 7.3. E-C CH2 Diag: Displays E-C CH2 information at different data processing stages. The following are the submenus  E-C CH2 Diag  Dcal  DRx  Z  Raw  Smt  Use to scroll through to diagnostic E-C CH2 Diag Submenu.
  • Page 55 CODEL Technical Manual 7.4. E-C CH3 Diag: Displays E-C CH3 information at different data processing stages. The following are the submenus.  E-C CH3 Diag  Dcal  DRx  Z  Raw  Smt  Use to scroll through to E-C CH3 Diag Submenu.

  • Page 56: Vis Diag

    CODEL Technical Manual 7.5. Vis Diag: Displays Vis Diag. The following are the submenus.  Vis Diag  Vis DTx  Vis DRx  Vis Z  Vis Raw  Vis Smt  Relay Output  Use to scroll through to Vis Diag configuration Submenu.

  • Page 57: Setup Mode

    CODEL Technical Manual 7.6. Exit: Allows user to exit to main menu.  Use to scroll through to Exit and press to exit to main menu. 3. DIAGNOSTICS 3. DIAGNOSTICS Exit 8. Setup Mode: Setup Mode allows users to Setup instruments. An overview of Setup mode submenus are shown below.
  • Page 58 CODEL Technical Manual  The most significant digit is highlighted use Increment or Decrement. Set EC1 TARGET 00000  Press to move cursor to next most significant digit. Repeat above procedure to increment or decrement and press move cursor to next digit and finally press to exit EC CH1 CAL.

  • Page 59: Parameters

    CODEL Technical Manual  Press to move cursor to next most significant digit. Repeat above procedure to increment or decrement and press move cursor to next digit and finally press to exit EC CH3 CAL. 8.1.5. VIS CH ZERO CAL: Allows user to activate VIS CH Zero Cal.

  • Page 60: Span Factor

    CODEL Technical Manual Set Protocols CODEL 8.2.2. Comms Address 1: Allows user to change comms address.  Use to scroll through to Comms Address 1. Comms Address  Press to set Comms Address after using to scroll through and choose Comms Address to be set.
  • Page 61 CODEL Technical Manual  The most significant digit is highlighted use Increment or Decrement. Set EC1 S.F 00.000  Press to move cursor to next most significant digit. Repeat above procedure to increment or decrement and press move cursor to next digit and finally press to exit EC1 Span Factor.
  • Page 62 CODEL Technical Manual move cursor to next digit and finally press to exit EC2 Span Factor. 8.3.3. EC2 Offset: Allows user to adjust EC2 Offset.  Use to scroll through to EC2 Offset. EC2 Offset 00000  The most significant digit is highlighted use Increment or Decrement.
  • Page 63 CODEL Technical Manual  Press to move cursor to next most significant digit. Repeat above procedure to increment or decrement and press move cursor to next digit and finally press to exit EC3 Offset 8.3.3.3. VIS Span Factor: Allows user to adjust VIS Span Factor.
  • Page 64 CODEL Technical Manual 8.4. mA Output: Allows user to setup mA output configuration. The following are the submenus.  mA Output  Abs Location  Type  Validity State  Smoothing Coeff  Span  Zero  4 mA DAC ...
  • Page 65 CODEL Technical Manual 8.4.3. Validity State: Allows user to set up the Validity state in case of data invalid situation. The following are the sub menus.  Validity State  Set Validity State  Use to scroll through to Validity state submenu.
  • Page 66 CODEL Technical Manual  Use to change the smoothing coefficient in hexadecimal. Smoothing Coeff: 0x000A  Press to move cursor to next most significant digit. Repeat above procedure to increment or decrement and finally press to set smoothing coefficient and exit.
  • Page 67 CODEL Technical Manual 8.4.6. Zero: Allows user to set up range for Zero mA. The following are the submenus.  Zero  Set Zero  Use to scroll through to Zero submenu. Zero: 0x0000 8.4.6.1. Set Zero: Allows user to set range for Zero mA.

  • Page 68: Relay Output

    CODEL Technical Manual Set 4mA DAC: 0x0000  Press to move cursor to next most significant digit. Repeat above procedure to increment and decrement and finally press to set 4mA DAC and exit. Set 4mA DAC: 0x0000 Set 4mA DAC:...
  • Page 69 CODEL Technical Manual 8.4.9. Exit: Allows user to exit to setup mode submenus.  Use to scroll through to Exit and press to exit to Setup mode submenus. EXIT Set Zero: Enter to Exit 0x0000 8.5. Relay Output: Allows user to setup Relay output configuration. The following are the submenus.
  • Page 70 CODEL Technical Manual  Press to move cursor to next most significant digit. Repeat above procedure to increment and decrement and finally press enter to exit Set Abs Location. Set Abs Location 0x01F6 Set Abs Location 0x01F6 Set Abs Location...
  • Page 71 CODEL Technical Manual Direction: Normal 8.5.3.1. Set Direction: Allows users to set direction status of relay.  Press to access Set direction sub menu. Set Direction: Normal  The Relay State Options. Normal Reverse  Use to scroll through different relay state options and press to exit.

  • Page 72: Rtcc

    CODEL Technical Manual Level: 0x0032 8.5.5. Data Type: Allows users to setup data type settings to read data from absolute data location. The following are the submenus.  Data Type  Set Data Type  Use to scroll through to data type submenu.
  • Page 73 CODEL Technical Manual  Use to scroll to RTCC. 4. Setup mode 4.7. RTCC  Press to view RTCC sub menu. Time 15:35:59 8.6.1. Time: Allows user to setup clock. It has the following sub menu.  Set Time. 8.6.1.1.
  • Page 74 CODEL Technical Manual 8.6.2. Date: Allows user to setup date. It has the following sub menu.  Set Date 8.6.2.1. Set Date: Allows user to set date.  Use to scroll through to Date. Date 15/02/2017  Press to access set date sub menu.

  • Page 75: Eeprom

    CODEL Technical Manual 8.7. EEPROM: Allows user to read and write data into memory. The following are the sub menus.  EEPROM  Read 0xXXXX  Write 0xXXXX to 0xXXXX  Exit  Use to scroll through to EEPROM. 4. Setup Mode 4.8.
  • Page 76 CODEL Technical Manual 8.7.2. Write: Allows user to write data into memory location. The following are the sub menus.  Write 0xXXXX to 0xXXXX (Write DATA to Memory)  Write 0xXXXX to 0xXXXX (Write DATA to Memory).  Use to scroll through to Write 0xXXXX to 0xXXXX.
  • Page 77 CODEL Technical Manual 8.7.3. Passcode: Allows user to set or enter a passcode. The following are the sub menus.  PassCode  Set New PassCode  Enter PassCode  Use to scroll through to PassCode. 4. Setup Mode 4.9. PassCode 8.7.3.1.
  • Page 78 CODEL Technical Manual 8.7.3.2. Enter PassCode: Allows user to enter passcode.  Press to access set Enter PassCode sub menu. Set New PassCode Enter to Confirm  Use to increment or decrement most significant digit in hexadecimal. Set New PassCode Enter to Confirm ...
  • Page 81 CODEL Technical Manual Page 1...

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