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Forbes Marshall CODEL TunnelTech205 Operating Manual

Tunnel atmosphere air quality monitor for no2
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OPERATING MANUAL
TunnelTech205
Tunnel Atmosphere
Air Quality Monitor for NO2
CODEL International Ltd.
Unit 4 , Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom
t : +44 (0) 1629 814 351
f : +44 (0) 8700 566 307
e : codel@codel.co.uk
web : www.codel.co.uk
Issue : B
Rev. : 1
Date : 11/07/22
Ref. : 100042

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  • Page 1 OPERATING MANUAL TunnelTech205 Tunnel Atmosphere Air Quality Monitor for NO2 CODEL International Ltd. Unit 4 , Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom t : +44 (0) 1629 814 351 f : +44 (0) 8700 566 307 e : codel@codel.co.uk web : www.codel.co.uk Issue : B Rev.
  • Page 2 Issue : B Rev. : 1 Date : 11/07/22 Ref. : 100042...
  • Page 3 CODEL Technical Manual CODEL International Ltd is a UK company based in the heart of the Peak District National Park at High priority is placed upon customer support. CODEL’s dedicated team of field and service Bakewell, Derbyshire. The company specialises in the design and manufacture of high-technology engineers will assist with any application problem instrumentation for the monitoring of combustion...
  • Page 4 CODEL Technical Manual Issue : B Rev. : 1 Date : 11/07/22 Ref. : 100042...

  • Page 5: Table Of Contents

    CODEL Technical Manual 1. Air Quality Monitor for NO2 2. Principles of Operation 2.1. Air Quality Monitor (AQM) ..........................3 2.1.1. NO2 Measurement ..........................3 Specifications 3.1. General ..............................6 Air Quality Monitor – NO2........................6 3.2. 3.3. Tunnel Display Unit (TDU) ........................6 3.4.
  • Page 6 CODEL Technical Manual 6.10. Set-Up Mode (Mode 5) ..........................21 6.10.1. Security Code Entry .......................... 21 6.10.2. Configure O/P 1 & 2 .......................... 22 6.10.3. Alarms ............................... 25 5.2.4.6.10.4. Parameters ......................... 25 6.10.5. Identity ............................... 26 6.10.6. Protocol ............................. 26 6.10.7.
  • Page 7 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. Caution, risk of danger.
  • Page 8 CODEL Technical Manual Issue : B Rev. : 1 Date : 11/07/22 Ref. : 100042...

  • Page 9: Air Quality Monitor For No2

    CODEL Technical Manual Page 1 1. Air Quality Monitor for NO2 NO2 is produced naturally by the combustion processes within the internal combustion engine and is emitted from the tail pipes of all types of vehicles. NO2 is also particularly toxic and prolonged exposure to levels as low as a few hundred parts per billion will have a detrimental effect on human health.
  • Page 10 CODEL Technical Manual Page 2 Figure 1: System Arrangement Issue : B Rev. : 1 Date : 11/07/22 Ref. : 100042...

  • Page 11: Principles Of Operation

    CODEL Technical Manual Page 3 2. Principles of Operation 2.1. Air Quality Monitor (AQM) 2.1.1. NO2 Measurement 2.1.1.1. Measurement Principles By measuring the amount of blue light absorption along a specific measurement path the concentration of NO2 in that path can be determined. It is important to minimise the impact that interfering absorption elements will have on the measurement.
  • Page 12 CODEL Technical Manual Page 4 A parameter, ‘Y’(blue) is defined, which is a measure of the light attenuation of the blue light beam, thus: ‘Y’(blue) 90,000 - (set cal) x DRblue/DTblue where: DRblue is the received detector signal for the blue light channel. DTblue is the detector signal from the transmitted blue light.
  • Page 13 CODEL Technical Manual Page 5 Zero calibration may be configured to be activated: Manually from the TDU keypad Automatically from the TDU clock (up to 1 week intervals) Remotely from the TDU logic input (volt-free contact input into +PS/0PS terminals Issue : B Rev.

  • Page 14: Specifications

    CODEL Technical Manual Page 6 3. Specifications 3.1. General Construction corrosion resistant polyester-coated aluminium housings sealed to IP67 (AQM); IP66 (PSU & TDU) Electro-magnetic immunity shielded to comply with 73/23/EEC - low voltage and 89/336/EEC-EMC Ambient temperature C to +50 Air Quality Monitor –...

  • Page 15: Basic Equipment Supply

    CODEL Technical Manual Page 7 4. Basic Equipment Supply 4.1. Standard Supplied Items CODEL will supply the following equipment: NO2 Air Quality Monitor(s) each fully assembled with diffusion tube and reflector with flow- through cell and fitted with : 1 x 4-core interconnecting cable (5m) between the AQM and the junction box 1 x 2-core interconnecting cable between the AQM reflector and the junction box 1 x Junction box for each AQM (to IP66 specification), suitable for 6-core cables and complete with 3 x cable glands...

  • Page 16: Installation

    CODEL Technical Manual Page 8 5. Installation WARNING! Be sure to observe all necessary safety precautions at all times during installation. 5.1. Check the Equipment After unpacking the equipment check that all items are present using the packing list provided. 5.1.1.

  • Page 17: Tunnel Display Unit (Tdu)

    CODEL Technical Manual Page 9 To mount the PSU first remove the cover by loosening the four captive screws. Secure the case to a firm support by use of the four mounting holes, one in each corner. Since the mounting holes are located outside the seal of the case it is not necessary to seal the mounting holes after installation, nor is it necessary to remove the circuitry from the case for installation.

  • Page 18: Connections

    CODEL Technical Manual Page 10 5.2. Connections WARNING Wiring should only be undertaken by a qualified technician. The following diagrams illustrate the connections for the equipment. NOTE: Only use the O/P 3 and 4, 1Amp outputs connections on the PSU. 5.2.1.

  • Page 19: Connection Schedule J-Box Configuration 1, (For Aqm & Tdu Up To 1Km Apart)

    CODEL Technical Manual Page 11 If the DDU is to be mounted apart from the sensor probe at a distance greater than 100m, then it is necessary to use a junction box due to voltage drop over long cable distances. 5.2.2.

  • Page 20: Connection Schedule J-Box Configuration 2, (For Aqm & Tdu Up To 200M Apart)

    CODEL Technical Manual Page 12 5.2.3. Connection Schedule J-Box configuration 2, (for AQM & TDU up to 200m apart) Figure 10: J-Box Connection Schedule, Config 2 RS485 Mains power Transceiver 48V DC Junction Box Heated mirror 4 – 20mA Figure 11 : Alternative J-box Connection Diagram Issue : B Rev.

  • Page 21: Tdu Operation

    CODEL Technical Manual Page 13 ① ② ➂ Figure 12 : Power Supply Unit ① Mains fuse ② Mains input connection ③ 48V DC outputs ④ 48v output fuses 6. TDU Operation Issue : B Rev. : 1 Date : 11/07/22 Ref.

  • Page 22: Introduction

    CODEL Technical Manual Page 14 6.1. Introduction After the instrument has been commissioned it will measure the NO2 levels between the transceiver and the reflector and produce an output proportional to the NO2 levels. The TDU’s integral 32-character display also shows the calculated levels.

  • Page 23: Key Operation

    CODEL Technical Manual Page 15 6.4. Key Operation Figure 13: TDU Keypad Mode key Enter key Data Valid LED, green Alarm LED, red Up/Down keys 32 character Back lit LCD screen Mode Key: Each mode is accessed sequentially by each push of the MODE key. Figure 13: TDU Keypad illustrates the display and keys of the TDU.

  • Page 24: Program Tree

    CODEL Technical Manual Page 16 6.5. Program Tree Figure 14 illustrates the main program of the instrument; where an operating mode is complex an extra program tree is illustrated. Figure 14 : Program Operation Tree 6.6. Operating Mode In this mode of operation displayed gas concentration may be observed. When in this mode, the display will appear similar to that shown below.

  • Page 25: Parameter Mode (Mode 2)

    CODEL Technical Manual Page 17 6.7. Parameter Mode (Mode 2) 6.7.1. Identification From this option, the analyser type, its program number, and the device identity of the instrument may be displayed. • Instrument type - NO2 • EPROM number - will display the communications EPROM ID •...

  • Page 26: Chamber

    CODEL Technical Manual Page 18 OFF – option not selected. ON – option selected. Next Cal. time/date to next calibration when using timed interval. 6.8. Chamber Press the MODE key until the number 3 is seen in the top left corner of the display; the main display will show ‘Not applicable’.

  • Page 27: Temperature

    CODEL Technical Manual Page 19 6.9.1. Detector Outputs Detector output levels are displayed here. The level of Dr & Dt should be between 15,000 and 25,000. ….. and after the smoothing filter has been applied; 6.9.1. Temperature The temperature measurement value is displayed here; this is an indication of the optical block temperature. 6.9.2.
  • Page 28 CODEL Technical Manual Page 20 6.9.4.1. Fault Condition By pressing the arrow key the current fault condition can be observed. To display the current fault condition, press the ENTER key while this is displayed. This display mode is automatically selected by the instrument, should a fault condition occur. The following fault conditions are recognised by the instrument : •...

  • Page 29: Set-Up Mode (Mode 5)

    CODEL Technical Manual Page 21 6.10. Set-Up Mode (Mode 5) All operating parameters – output settings, alarms, calibration, etc. – can be changed from this mode. To prevent any unauthorised changes, the user must enter a four number code before the mode can be entered. After this mode has been selected, the instrument will suspend its operation and the Data Valid LED will extinguish.
  • Page 30 CODEL Technical Manual Page 22 Figure 16 : Set-Up Mode Tree 6.10.2. Configure O/P 1 & 2 The analogue current loop output is set up from this mode. Press the ENTER key while this display is shown to select it, then press the ARROW keys to step through the available options. Press the ENTER key to enter each option and change the displayed parameter.
  • Page 31 CODEL Technical Manual Page 23 Select the required span using the ARROW keys for each digit. The ENTER key is pressed to enter the value of each digit. The units will be displayed in ppb. The current value will be displayed for 1 second when this option is entered.
  • Page 32 CODEL Technical Manual Page 24 Issue : B Rev. : 1 Date : 11/07/22 Ref. : 100042...

  • Page 33: Alarms

    CODEL Technical Manual Page 25 Now repeat the above procedure to configure output 2. • Alarm 1 & 2 A contact output is available to warn of a high gas concentration. The units for the alarm ppb. The instrument requires a level that the output will be triggered. Set the desired level with the ARROW keys. 6.10.3.

  • Page 34: Identity

    CODEL Technical Manual Page 26 Note: It is important to make a note of this new number as it will not be possible to change the instrument set- up without it. 6.10.5. Identity The communication address for the serial communication output is set here. Each device on the serial communications highway should have a unique communications address identity number.
  • Page 35 CODEL Technical Manual Page 27 From this option the calibration routine may be set up as follows: • Set Cal Data Set the number of measurement cycles used for the zero calibration. • Zero Cal The zero calibration procedure is activated here. The purge time countdown is displayed in seconds and the calibration measurement cycle countdown is also displayed.
  • Page 36 CODEL Technical Manual Page 28 Logic Input NO option inhibited. Cal Alarm this will switch Alarm 1 relay when the calibration routine is in progress. option inhibited. Issue : B Rev. : 1 Date : 11/07/22 Ref. : 100042...

  • Page 37: Commissioning

    CODEL Technical Manual Page 29 7. Commissioning 7.1. AQM (NO2) 7.1.1. Communications (see also Appendix A for further information) Firstly, access the Set-Up mode in the TDU, then set: Identity Protocol Codel Baud 4800 …….. and EXIT the Set-Up mode. 7.1.2.

  • Page 38: Calibration No2

    CODEL Technical Manual Page 30 Rx Gain Tx Gain Figure 17 : Gain Adjustment 7.1.5. Calibration NO2 Providing that the heater control and detector data are correct, the sensor may be calibrated from the 'Calibration’ sub-menu in the TDU set-up mode. Set the number of calibration cycles to 200 then calibrate. The monitor will now calibrate to an assumed zero level.

  • Page 39: Maintenance

    CODEL Technical Manual Page 31 8. Maintenance 8.1. General The equipment is designed for low maintenance. The sensors utilise the latest microprocessor technology and have no moving components; they require no routine maintenance. 8.2. Emergency Shutdown/Isolation Procedure Shut OFF the power to the PSU and the whole system will close down. Issue : B Rev.

  • Page 40: Data Communication

    CODEL Technical Manual Page 32 9. Data Communication 9.1.Hardware Configuration 9.1.1.System The Tunnel Display Unit (TDU) communicates with the AQM via a local data bus. The TDU also acts as a ‘gateway’ for diagnostic data from the devices on the local data bus; such data can be accessed by an integral RS485 serial port in the TDU.

  • Page 41: Address Numbers

    CODEL Technical Manual Page 33 9.2. Address Numbers Because communications between the TDU and the sensor is serial digital it is necessary for each sensor to be allocated an address number. 9.2.1.AQM Address The address of the AQM is set by removing the rear end plate of the sensor. Mounted on this plate is a circuit board that carries all the cable connections.

  • Page 42: List Of Figures

    CODEL Technical Manual Page 34 10. List of Figures Figure 1: System Arrangement ..............................2 Figure 2: AQM Measurement Elements ........................... 3 Figure 3 : Air Quality Monitor – NO2 ............................. 8 Figure 4 : Power Supply Unit ..............................8 Figure 5 : Data Display Unit ..............................

  • Page 43: Appendix A : Standard Modbus Communication With Codel No2 Tdu

    CODEL Technical Manual Page 35 Appendix A : Standard MODBUS Communication with CODEL NO2 TDU Summary Using standard MODBUS protocol function 03 allows a host to obtain the contents of one or more holding registers in the CODEL NO2 TDU. 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 44 CODEL Technical Manual Page 36 Reference: AEG Modicon Modbus Protocol Reference Guide PI-MBUS-300 Rev. D. Each register is defined to be 2 bytes wide. Modbus Register Location 0070h NO2 Data 0001h = 1ppb, 0064h = 100ppb Data Register Locations at CODEL TDU for Interrogation using Standard MODBUS are shown in the following table: Issue : B Rev.
  • Page 45 CODEL Technical Manual Page 37 REGISTER FORMAT CUSTOMER SPECIFIC DETAILS Location Analyser Data Data Units Typical Range Value Description 0070 instantaneous XXXX 1ppb 0-2000 XXXX NO2 measurement 0071 Not Used 0072 Not Used 0073 Not Used 0074 Not Used 0075 Not Used 0076 Data Valid...
  • Page 46 CODEL Technical Manual Page 38 Revision and amendment register Date source Section / page Description New Revision 17/03/22 Front cover Front cover update Title changed from “Technical” manual to 23/05/22 YM request Front cover “Operating” Manual analyser screen updated to current display to show : Pm741 6.9.1...
  • Page 47 CODEL Technical Manual Page 39 Issue : B Rev. : 1 Date : 11/07/22 Ref. : 100042...

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