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CODEL Tunnel Tech 500 Series Technical Manual

Tunnel atmosphere monitoring system co/no/no2
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CODEL
Station Building, Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom
t : +44 (0) 1629 814 351
Issue: A
TECHNICAL MANUAL
Tunnel Tech 500 Series
Tunnel Tech 501
Tunnel Tech 502
Tunnel Tech 503
Tunnel Tech 504
Tunnel Tech 505
Tunnel Tech 506
Tunnel Tech 507
Tunnel Atmosphere Monitoring System
(CO/NO/NO
CODEL International Ltd.
f : +44 (0) 8700 566 307
Revision:3
Page 1
–
CO/NO/NO
–
CO/NO
–
CO
–
NO
–
NO
2
–
CO/NO
–
NO/NO
)
2
e : codel@codel.co.uk
Date:16/01/2019
Operation and Maintenance
2
2
2
web : www.codel.co.uk
Ref:100351

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  • Page 1 CODEL Page 1 Operation and Maintenance TECHNICAL MANUAL Tunnel Tech 500 Series Tunnel Tech 501 – CO/NO/NO Tunnel Tech 502 – CO/NO Tunnel Tech 503 – Tunnel Tech 504 – Tunnel Tech 505 – Tunnel Tech 506 – CO/NO Tunnel Tech 507 –...
  • Page 2 CODEL Operation and Maintenance Manual Issue: A Revision:3 Date:16/01/2019 Ref:100351...
  • Page 3 CODEL Operation and Maintenance Manual 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 4 CODEL Operation and Maintenance Manual Issue: A Revision:3 Date:16/01/2019 Ref:100351...

  • Page 5: Table Of Contents

    CODEL Operation and Maintenance Manual Contents System Description ............................1 The Tunnel Tech 500 Series Concept ....................1 CO, NO, and NO ........................... 2 Power Supply Unit (PSU) ........................3 Principles of Operation ........................... 4 Electro Chemical Cell – CO/NO/NO .....................
  • Page 6 CODEL Operation and Maintenance Manual Issue: A Revision:3 Date:16/01/2019 Ref:100351...
  • Page 7 CODEL Operation 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.
  • Page 8 CODEL Operation and Maintenance Manual Issue: A Revision:3 Date:16/01/2019 Ref:100351...

  • Page 9: System Description

    1 System Description 1.1 The Tunnel Tech 500 Series Concept Tunnel Tech 500 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...

  • Page 10: Co, No, And No

    Operation and Maintenance Manual The monitoring stations, Figure 1, provide all required measurements and outputs at each monitoring location within the tunnel. Figure 1: Tunnel Tech 500 Series - Monitoring Station 1.2 CO, NO, and NO CO, NO and NO are measured using electrochemical cell technology.

  • Page 11: 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 500. mains input connections Figure 2: Tunnel Tech 500 Series - power supply unit 24V DC Issue : A Rev. : 3 Date : 13/11/2018 Ref.

  • Page 12: Principles Of Operation

    CODEL Operation and Maintenance Manual 2 Principles of Operation 2.1 Electro Chemical Cell – CO/NO/NO In order to measure the level of gas (CO/NO/NO ), the Tunnel Tech 500 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.

  • Page 13: Specification

    CODEL Operation and Maintenance Manual 3 Specification 3.1 Technical data: Optional Measurement principle: Electrochemical Cell Measurement units: Nominal measurement range 0 to 800 ppm 0 to 160 ppm 0 to 10 ppm (typical): Measurement range (typical): 1 to 300 ppm...

  • Page 14: Construction And Enclosure

    CODEL Operation and Maintenance Manual 3.2 Construction and Enclosure: Aluminium Steel 316 (optional) Construction: Epoxy Coated Die-Cast Aluminium Stainless Steel 316L or Stainless Steel 316Ti Colour/Finish: Black (RAL 9005 - Jet Black) Silver/Ground, Grain 240 (S/S) (Aluminium) Enclosure Rating: Designed to IP66 (IP69K Optional)

  • Page 15: Optional Items

    CODEL Operation and Maintenance Manual 3.5 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)

  • Page 16: Cables

    CODEL Operation and Maintenance Manual 3.7 Cables Recommended Cable Minimum Specification Power Supply Cable: Shielding: Shielded to enclosure Cores / Wire Diameter: 2 Core / 1mm Typically Supplied by: Customer RS485 ModBUS Cable: Shielding: Shielded away from enclosure Cores / Wire Diameter: 2 Core / 0.5mm...

  • Page 17: Installation Material

    CODEL Operation and Maintenance Manual 3.8 Installation Material Installation Bolts Sensor Body: No.: Dimensions: 180 (L) x 180 (H) (mm) Bolt Thread Type: Bolt Length: 60 (mm) or to suit application 24V Power Supply: No.: Dimensions: 180 (L) x 180 (H) (mm)

  • Page 18: Installation

    CODEL Operation and Maintenance 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 19 CODEL Operation and Maintenance Manual 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 source not found.Figure 4. Figure 4: PSU – arrangement...

  • Page 20: Connections

    CODEL Operation and Maintenance Manual 4.2 Connections Wiring should only be undertaken by a qualified technician. The following electrical schematic illustrates the connections for the Tunnel Tech 500 Series system. Figure 5: Electrical Schematic | 12 Issue : A Rev. : 3 Date : 13/11/2018 Ref.
  • Page 21 CODEL Operation and Maintenance Manual 4.2.1 Power Connection: Place 24V screened cable through the gland and connect to CON1 24V power input as described below. Figure 6: Power Connection 4.2.2 RS485 Connection Figure 7: RS485 Connection | 13 Issue : A Rev.
  • Page 22 CODEL Operation and Maintenance Manual Figure 8: Wiring diagram 4.2.3 PCB Identification and connections 4.2.3.1 Enclosure Lid Control/Display PCB ❶ ❶ ① 24VDC Power input ② RS485 communications ❷ ❷ Electrochemical Cell (E-Cell) PCB 4.2.3.2 Enclosure Base mA output PCB...

  • Page 23: 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 500 (instrument’s name).

  • Page 24: E-Cell Commissioning

    CODEL Operation and Maintenance Manual NOTE: If the display unit is unable to communication with the attached peripheral the screen will display a communications fault. This will show an “E-Cell Comm Fault” or “Vis Comm Fault” respective of where the fault resides.
  • Page 25 CODEL Operation and Maintenance Manual 5.3.2 Detector levels From the menu position below the detector levels can be observed. In zero conditions the E-Cell detector levels should be: Approx. 26215 for CO (cell 1) Approx. 26215 for NO (cell 2) Approx.

  • Page 26: Ma Output Setup

    CODEL Operation and Maintenance Manual 5.4 mA Output Setup The mA output menu allows the user to configure the measurand, zero and span information for the attached mA boards. In addition, the menu allows the user to simulate a given value on any attached board to test each individual channel.
  • Page 27 CODEL Operation and Maintenance Manual Using the keys, manipulates the onscreen value with the key moving to the next available location or setting the entered value if all 5 fields are complete. 5.4.3 mA Span Value When setting the Span value on the mA board, the menu system uses the measurand to determine how to handle the requested information.

  • Page 28: Relay Output Setup

    CODEL Operation and Maintenance Manual 5.5 Relay Output Setup The relay output menu works in conjunction with the mA output menu, allowing the user to independently configure the relay measurand, direction and trigger level for each individual channel. 5.5.1 Relay Trigger Measurand The first menu accessible Is the measurand selection menu, this menu displays the measurand on which the alarm should trigger.
  • Page 29 CODEL Operation and Maintenance Manual 5.5.2 Relay Direction The relay system allows the user to configure if the relay channel is set to normally open or normally closed. This option is useful in fail-safe environments where power outages are common, forcing the connected relays to switch in case of power failure.

  • Page 30: Time And Date

    CODEL Operation and Maintenance Manual 5.6 Time and Date The TunnelTech 500 contains a real-time clock and calendar. Allowing the system to keep up to date with maintenance. On entering the RTCC setup menu, the user is presented with the device’s current time and date Press the keys to cycle between the time and date.
  • Page 31 Replacement of the electrochemical cell board is required every 18 months. The replacement cells will be supplied from CODEL pre-calibrated complete with card. Failure to replace cells will invalidate the warranty and performance of the analysers after this time cannot be guaranteed.

  • Page 32: Maintenance

    Operation and Maintenance Manual 6 Maintenance The Tunnel Tech 500 Series system is designed for low maintenance. The sensors utilise the latest microprocessor technology. The TunnelTech 500 sensor uses an infrared source that has a life expectancy of over 3 years.
  • Page 33 When the date elapses the alarm LED illuminates to warn the user that the E-Cells are due to be replaced. Every 18 months it is required to replace the electrochemical cell. The replacement cells will be supplied from CODEL pre-calibrated complete with PCB. To check the maintenance due date for the E-Cell, refer to section 5.3.1 Ensure the device is disconnected from the power before performing any internal maintenance To remove the electrochemical cell, open the TT700 casing and locate the E-Cell.
  • Page 34 CODEL Operation and Maintenance Manual Figure 10: E-Cell identification Remove the ribbon cable connecting the display/control board and the E-Cell board. There is no locking mechanism, and the ribbon cable will uncouple from its sockets when pulled away from the board.
  • Page 35 CODEL Operation and Maintenance Manual Remove the 6x nuts from the four corners of the E-Cell, along with the washers. Ensure that these are kept safe. Figure 12: E-Cell PCB Removal Slowly remove the E-Cell from the Unit. Insert the new E-Cell in to the unit, observing the cell orientation and replace the nuts and washers.

  • Page 36: Spare Parts

    CODEL Operation and Maintenance Manual 6.2 Spare parts 6.2.1 Replacement E-Cell boards: Species Part number 991.606 CO, NO 991.604 CO, NO, NO 991.598 991.608 NO, NO 991.614 991.610 6.2.2 mA/Relay Card: 803.604D Figure 13: TunnelTech 500 Spares / accessories | 28 Issue : A Rev.

  • Page 37: Data Communication

    Current Outputs mA 1 Master 9-36V and Relays Current Outputs mA 2 and Relays Figure 14: Tunnel Tech 500 Series - system configuration | 29 Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 100351 P a g e...

  • Page 38: Address Numbers

    CODEL Operation and Maintenance Manual 7.2 Address Numbers Address numbering is delegated to 2 UARTs. (Universal Asynchronous Receiver/Transmitter). The first UART is external comms to the display unit on a network. The 2 UART is for internal communication to all peripheral devices, such as the E-Cell and Vis.
  • Page 39 CODEL Operation and Maintenance Manual | 31 Issue : A Rev. : 3 Date : 13/11/2018 Ref. : 100351 P a g e...

  • Page 40: List Of Figures

    8 List of Figures Figure 1: Tunnel Tech 500 Series - Monitoring Station ..................2 Figure 2: Tunnel Tech 500 Series - power supply unit 24V DC ................3 Figure 3: TunnelTech 500 – Mounting Dimensions ....................10 Figure 4: PSU – arrangement ..........................11 Figure 5: Electrical Schematic ..........................

  • Page 41: Appendix 1: Modbus Communication & Rs485 Connection

    9 Appendix 1: MODBUS Communication & RS485 Connection The MODBUS protocol output of the Tunnel Tech 500 Series AQM is taken via the 4-way plug. RS485 connection is also available and the following wiring schematic and photograph illustrate the connections for this feature.
  • 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 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 Operation and Maintenance Manual Standard baud rate 4800 Bits per byte 1 start bit 8 data bits (least significant sent first) 1 stop bit no parity The MODBUS output from the TT AQM is at 4800 baud format: 1 start bit, 8 data bits, no parity, 1 stop bit.

This manual is also suitable for:

Tunnel tech 501Tunnel tech 502Tunnel tech 503Tunnel tech 504Tunnel tech 505Tunnel tech 506 ... Show all

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