2007/08 Edition

Systems for tunnels

Compliant to the European Parliament Directive 2004/54/EC
relative to the minimum safety requirements for tunnels
on the TERN - Trans European Road Network.
850C - 90 400C - 120
Certified
Introduction
Italy
In use:
- Motorway network 517 tunnels for a total of 283 km
- To be adapted: 378 tunnels
- New works : Passante Genova, Gronda di Ponente,
new mountain motorway pass
Bologna-Florence
(chart 1)
Axis
Patrai
Sofia
Bucarest
Portugal
Portugal
Spain
North triangle
Section
Via Egnatia
Pathe
Sofia-Kulata
Lisbon - Valladolid
La Coruna - Lisbon
Siviglia - Lisbona
Helsinki - Vaalimaa
Start of Works
2006
2008
2010
2010
Started
Started
2015
Europe
In use (excluding Italy): 171 tunnels (all part of the
Trans European Road Network) New: 95 tunnels
Road tunnels are essential infrastructures to improve road networks in hilly areas and to cross cities and built up areas. When
building quite short tunnels, in the order of a hundred meters, the work is almost exclusively building work and the possible
technological fittings, such as for instance lighting, are optional and there are no particular requirements. It is quite a different matter
when the tunnel is long, where the lighting, ventilation, luminous signs, air conditioners and fire-prevention systems are all essential
both during normal use and in the case of an emergency. The complexity of the project and the entity of the consequent risks in
emergency situations, increase according to the length of the tunnels and the amount of traffic, to the extent where long tunnels can
be considered as colossal works, not only from a tunnelling point of view but also with regards to the level of technology required.
Since all the technological equipment runs on electricity, the primary role of this system is clearly evident which must be reliable
and safe, but it appears that, also in this sector, there is the traditional underestimation of electrical installations; this can be seen by
the total lack of regulations or guidelines provided by CEI and CENELEC. Even the EC Directive 2004/54, that constitutes the most
important document on minimum European safety regulations for building tunnels, dedicates just a few lines to the requirements of
the electrical fittings and unequivocally reveals a practically total lack of involvement of any experts in our sector. The main
consequence of this deficiency is the lack of consistency in electrical regulations, mainly established from case to case, by the project
owners, or individual engineers in the tender document specifications. The lack of specific product regulations, harmonized at a
European level, prevents constructors from designing standard electrical components, checked using standardized and unequivocal
testing systems and encourages impromptu amendments to order or even installed by the electricians using makeshift methods.
This habit can be justified for sporadic work and constructions, but this is no longer the case when dealing with road tunnels as,
during the second half of the last century, there was an exponential increase, not only in quantity and importance, but also and
especially in safety issues; recent tragic accidents prove how urgent it is to consider the machines, electrical and electronic devices
and fittings from a global point of view, in order to search for a synergy which will lead to a more reliable construction and installation
technologies.
Palazzoli, a company which has been specializing in electrical components for application in difficult environments for over a century,
has recently researched the specific problems of tunnels in great depth and involved both experts working in this sector and also
experts in electrical accident prevention standards. Following the results of this research, and in view of the present and future
development in the sector, it has designed a series of standard IMQ certified components, using innovative concepts, coherent with
the existing standards with similar purposes.
This report summarizes the fundamental concepts that arose during the aforesaid research and we trust it can constitute a guide for
workers and a contribution for the national and international regulatory authorities who deal with safety in road tunnels. As can be
noted in chart 1, the work prospects in this fundamental sector, both at a national and European level, and also short term, are
anything but negligible and deserve the attention of the professionals and businessmen working in this field and, at least, a specific
CEI Guide that officially endorses and completes the workmanship standard concepts referred to in this report.
LIST OF THE MOST IMPORTANT ROAD TUNNELS:
PRIORITY DEVELOPMENT PROJECTS FOR ROAD NETWORKS INCLUDED IN ANNEX III OF DECISION N 1692/96 CE
2
Systems
for tunnels
Axis
Great Britain
Benelux
Gdansk
Vienna
Ireland
Great Britain
Section
Various
Gdansk - Katowice
Katowice - Brno
Brno - Vienna
Dublin - Larne
Hule - Liverpool
Start of Works
2010
2010
2010
2009
2010
2015
3
Italy only:
Juridical regulations:
Law 186/68
Ministry decree 31-3-95
Ministry decree 6-11-99
Ministry decree 5-6-2001
Systems Standards:
CEI, UNI
(See details on page 4)
CEE (including Italy)
Juridical regulations:
Directive
2004/54/CE
Systems Standards:
CEI EN, CIE, CEN
(See details on page 4)
The legislative and regulatory situation regarding tunnels is extremely vast and complex, as it also involves the protection of the
environment, the highway code, safety at worksites and often has to include provisions issued by the local authorities.
This paragraph only refers to the regulations and laws which refer to technological systems, which have to comply with the particular
requisites typical of tunnels.
A distinction is made between the provisions which have a juridical value, such as EC Directives, laws, decrees, ministerial circular
letters, from those which are purely technical, such as standards, recommendations, guides, reports, technical specifications. The
latter can only assume a coercive value if they are imposed by juridical dispositions or by tender contracts stipulated between a
principal and a supplier. It should be mentioned that, as in most cases these works are subject to public tenders, which are generally
extended at a European level, the non-juridical rules have to at least be coherent with the standards, guidelines or reports issued by
recognized authorities. If there are no specific publications, the workmanship standards must be based on scientifically coherent
standards which aim to pursue and refer to similar regulated situations.
An example of the legislative and regulatory framework can be seen in the chart below:
This is a European Directive which outlines project criteria, levels of responsibility and the minimum safety requirements for tunnels
on the TERN (Trans European Road Network) as defined in Decision 1692/96/EC. Despite referring only to the most important
tunnels in Europe, it constitutes a fundamental reference document. It is quite specific with regards to the geometry, conformation of
the tunnels and the functional and safety technological services, such as ordinary lighting, emergency and safety lighting, luminous
road signs, ventilation and emergency signs, rescue and escape routes. It does not provide any particular details on the choice of
electrical materials and the design and installation criteria which must be used for electrical systems. It does not even make any
reference to the CEI EN standard, widely harmonized by IEC- CENELEC.
This is a fundamental framework law for electrical installations as it establishes the legal obligation to install the systems to top
workmanship standards. It recognizes that the CEI and UNI Standards have the undisputable prerogative of being the source of such
workmanship standards. This also confers legal validation to the Standards, though it does not make them mandatory. It is applicable
to the generality of cases and therefore also to tunnels. Law 46/90 however is not applicable as it refers to interior electrical fittings, even
if it can represent useful reference with regards to the assignment of the project, the works and functional electrical inspection and testing.
This refers to road signs and, in this case, the provisions relative to electrically rear-lit luminous road signs are interesting . It
implements the UNI1 2899-1 Standard that covers technical lighting. This Decree was integrated by Directive October 24 2000 and
M.D. July 11 2000.
This came immediately after the terrible fire that broke out in the Mont Blanc Tunnel and emphasizes the need for more precise
rulings, outlines the ways to limit the amount of dangerous vehicles in the tunnel and restrictions on speed and overtaking. From a
technical point of view, it established the principle of the relationship between the different regulations, with the functional and
geometrical features of the tunnels and traffic flow. It establishes the obligation to check that the lighting system complies with the
recommendations passed by CIE 88/90, referred to later, and the obligation of modification in the case of no compliance.
Legislative and
regulatory framework
The laws in details EC DIRECTIVE 2004/54/EC
LAW 186/68
M.D. MARCH 31 1995
M.D. DECEMBER 6 1999
This establishes the obligation for road tunnels which are 1000m or over, 500m on urban roads, to install SOS interphone columns
and fire-prevention extinguishers at the lay-bys, danger warning road signs spaced according to the sections of the tunnel, but in
any case at a distance of no less than 500m. When tunnels are 2000m or over it is necessary to install fire hydrants compliant to
UNI 45 every 200m. For tunnels which have surveillance systems or control centres, it is mandatory to prepare a safety manual
compliant to L.D. 626/94 (where the tunnel is considered a work place). The Decree set a deadline of June 30 2001 for tunnels to
comply with these requirements.
This is actually an extension of the deadline set for tunnel compliance pursuant to MD December 6 1999.
Whilst the juridical laws refer to the principles of generic matters, the technical standards provide in-depth information on the
individual topics and their various difficulties. In the case in question, it is necessary to divide the topic into at least three
separate issues: the electrical and electronic system with the relative components according to CEI Standards in Italy, to
CENELEC standards in Europe and to IEC standards at an international level.
These authorities coordinate with each other, and with marginal differences and a few exceptions, all the standards are
coherent with the IEC international publications; technical lighting intended as the design, installation and testing of lighting
parameters in reference to both natural and artificial light is regulated in Italy by UNI Standards. The accredited standards at
a European level are provided by CEN (European Committee for Standardization) where the Technical Committee 169 deals
with technical lighting and by CIE (Commission International de l'Eclarage) that exclusively studies technical lighting and has
a division (D4), specialized in road lighting and signs.
All other matters regarding the non-electrical performance of the machines, the non-electrical features of the materials and
dimensional unification are regulated in Italy by UNI and in Europe by CEN.
The electrical and electronic system and components used in tunnels are regulated, in a more or less relevant manner, by a
hundred or so CEI Standard documents.
The features that should be explicitly referred to in the specifications are listed below. It should be emphasized that the simple
specification imposition: "all the electrical and electronic systems and materials must comply to CEI Standards" is anything
but univocal. For instance, the plates used for domestic HI-FI systems which are 0.3 mm2 and insulated with light PVC, and
the cables which are fireproofed with mineral insulation all comply to CEI Standards. For each Standard only the abbreviated
title is indicated and, in brackets, the topics of specific interest for safety in tunnels.
The complete list of CEI Standards with relative European initialling, edition currently applicable and file number is available
free of charge from the website www.ceiuni.it:
CEI 11-1: High voltage systems and low voltage public distribution (Medium voltage cabins and lines, earthing systems);
CEI 11-35: Guide to the execution of user electrical cabins (cabins);
CEI 11-17: Cable lines (cables buried below pavements);
CEI 11-13/1: Assembled devices for protection and manoeuvre purposes (electrical panels);
CEI 17-5: Automatic switches (general distribution and protection of cables);
CEI 17-11: Manoeuvre and cut-off switches (general distribution and sectioning of individual users located inside the tunnel);
CEI 20-22/: Testing procedures for cables in fire conditions (to prevent the fire from spreading along the tunnel through the
electrical cables);
CEI 20-36/: Fire-resistance tests on cables under fire conditions (ability of the cables installed in the tunnel to function in
the presence of fire and for specific periods);
CEI 20-37/: Gas and fume tests on cables under fire conditions (ability of the cables installed in the tunnel to give off limited
quantities of toxic gas and fumes in the presence of fire);
CEI 20-38/1: Rubber insulated cables, which do not propagate fire and produce low levels of toxic gas and fumes with 0.6/1kV
voltage (cables usually suitable for electrical supplies in tunnels, when fire-resistance is not required or they are
fitted using the relative protection systems during installation );
CEI 20-39/1: Power cables with mineral insulation for voltages under 750V (cables which can function for at least 3 hours in
the presence of fire at temperatures up to the melting point of copper);
CEI 20-45: Fire-resistant cables insulated with an elastomer mix with a nominal voltage of 0.6/1 kV (cables which can
The Standards
in details
M.D. JUNE 5 2001
THE ELECTRICAL AND ELECTRONIC SYSTEM
4
Systems
for tunnels
CARATTERISTICHE GENERALI:
5
function for a limited period of time in the presence of fire in tunnels at temperature up to 830C; the flame-
resistance time is declared by the manufacturer and there are types which resist for up to 90 minutes);
CEI 22-16: UPS systems (sources of power reserves and protection complete with batteries and the possibility to combine
it with generator groups);
CEI 22-17: Activators for alternate current motors at various speeds ( activation and inversion of the ventilators installed in
the tunnel or in ventilation stations);
CEI 23-12: Plugs and sockets for industrial use ( connections which can be sectioned from the lighting systems or other
components installed in the tunnel);
CEI 32-1: Fuses (selective protection for devices and ventilators installed in the tunnel and which derive from backbone
cables);
CEI 34-15: Sodium vapour lamps;
CEI 34-21: Lighting apparatus to general standards;
CEI 34-22: Emergency lighting apparatus (apparatus which has incorporated autonomous sources which illuminate the
emergency escape routes or the SOS cabins);
CEI 34-33: Road lighting apparatus (this is the Standard which is most applicable to the symmetrical and asymmetrical
apparatus installed in tunnels);
CEI 44-5: Machine security. Electrical machine components (control panels for ventilation stations);
CEI 64-8/4: Low voltage electrical systems. Safety prescriptions (protection against direct and indirect contact, protection of
the wiring against power surges, sectioning and control applied to all parts of the electrical systems installed in
the tunnel and elsewhere);
CEI 64-8/5: Low voltage electrical systems. Choice and installation of the electrical systems (applicable to the general
specifications of the electrical systems installed in tunnels and elsewhere);
CEI 64-8/7: Low voltage electrical systems. Application in particular environments (this refers to section 714 relative to
lighting systems installed outdoors, including tunnels, and section 715 relative to systems installed in places
with high risk levels in the presence of fire, which outline the main principles to prevent the electrical wiring
from becoming the cause of the start or propagation of fire);
CEI 70-1: Protection index of the covering against solid bodies, dust and water (assessment of the IP level suitable for
electrical components installed in tunnels);
CEI 70-3: Protection index of the covering against collision (assessment of the IK level suitable for electrical components
installed in tunnels);
We can conclude this list of CEI Standards by commenting that, at present, there are no specific standards which regulate the
systems or materials destined for use in tunnels. In particular, the fire-proof levels are assessed, which intend to guarantee
that the electrical system continues to function even in the presence of fire, exclusively with regards to the cables. No types
of apparatus and no types of machines are taken in consideration from this point of view.
UNI11095 2003 Edition: This standard refers to the photometrical features of tunnels and is the fundamental reference
document in this report; it should be remembered that the UNI Standards, pursuant to Law 186/68, provide the prerogative of
workmanship standards and it seems justified to acknowledge this priority when faced with other incoherent standards or
recommendations. CIE Publication 88: This refers to the photometrical features in tunnels and comprises the fundamental
reference document of the M.D. of December 6 1999 mentioned above. Standards currently being updated: CEN
CR14380, 2003 Edition: This refers to the technical lighting standards in tunnels and is very similar to the UNI11085
Standard. This is recognised as a reference document for CEI Standards.
Circular letter 7735 dated September 8 1999. National Road Authorities General Head Office. This provides detailed
regulations regarding all aspects of technological systems installed in tunnels and is the fundamental documents for the ANAS
Technical Specifications. This circular letter was taken into account during the preparation of this report, though not
exclusively, as the electrical concepts have been extended.
THE OTHER STANDARDS
TECHNICAL LIGHTING
6
SYSTEMS
FOR TUNNELS
Socket-outlets and plugs
for electric fans
VENTILATION SYSTEMS
TUNNEL54 Series
page 9
Electric fan line bar
TUNNEL54 Series
page 9
GALLERIA PIANA - Messina Palermo motorway
125A TUNNEL54 Series electric fan supply with socket-outlet
and plug, certified for 400C for 120.
System made by EUROTEL S.r.l. of Agrigento.
400C - 120
INTEK certified
7
Projectors for lanes and
recesses
TUNNEL54 Series
page 10
Spurs for single-pole cable
TUNNEL54 Series
page 11
Spurs for multi-pole cable
TUNNEL54 Series
page 12
Projector line bar
TUNNEL54 Series
page 12
GALLERIA S. STEFANO DICAMASTRA (ME)
Spurs to lighting bodies with enclosures of the TUNNEL54
Series, certified for 400C for 120 and 850C for 90.
System installed by association of businesses:
Carlo Gavazzi / Brulli / S.I.E.G.
LIGHTING SYSTEMS
The TUNNEL54 system is FIREPROOF. The use of
metal, ceramics and heat-hardening resins ensures
maximum resistance to fire and corrosion. The
FIREPROOF approval guarantees that
the operating tests at 400C for 120
have been passed (A.N.A.S. circular
7735 of 8 September 1999) and at 850 C for 90
minutes (EN 50200).
Palazzoli in the road systems:
The quality and performance of
the Palazzoli products meet
the specifications for viaducts,
transformation cabinets, service
areas, turn-offs, etc even in areas
with ATEX explosion hazard.
TUNNEL54 SERIES SYSTEMS FOR TUNNELS
This is a range designed for the creation of electrical systems for ventilation and illumination inside
the galleries and road systems in compliance with the new European Directive 2004/54/CE and
current national regulations including for Italy A.N.A.S. circular 7735 of 8 September 1999.
The TUNNEL54 series consists of flameproof, smokeproof and rodentproof devices in alluminium
alloy or AISI 316L stainless steel. They are built to ensure continuous service even in fires and are
certified by internationally accredited laboratories.
The high degree of IP66 protection prevents penetration by humidity, pollution (gas, fumes, dust, etc)
that are typically present in tunnels.
AGAINST FIRE
WITHOUT
COMPROMISES
The TUNNEL54 interlocked socket-outlets for
electric fans in the dual versions 63A and
125A ensure operation at 400C for 120.
This performance is obtained only with rated
current circuit breakers at ambient
temperature, respectively at 400A and 200A
with closure power from 1250A.
GUARANTEED CABLE
PERFORMANCE
The unsurpassed resistance to heat of the
brass terminal blocks on a ceramic base and
the terminals with dual anti-loosening screws
are the only solution to ensure electrical
continuity up to 850C for 90.
COMFORT AND
SAFETY
The TUNNEL54 series projectors are the ideal
solution for lighting the galleries with
fluorescent T5 and T8 lamps up to 54W.
They are made of a single drawn piece
without welding seams and are therefore not
subject to corrosion.
8
Systems
for tunnels
Techniques and advantages
850C - 90
IMQ certified
400C - 120
INTEK certified
Technical data
pages 1415
Dimensions
page 15
Systems for tunnels
9
VENTILATION SYSTEMS
Socket-outlets with stop switch
and plugs for tunnel electric fans
Equipment:
provided with washers
and screws for fixing
accessories. Internal and
external earth terminal.
Characteristics:
upper side passage with F5
window.
Complementary items:
flanges with cable gland,
closing flanges and
fastening brackets on
page 13.
TUNNEL54 SERIES
Socket-outlets with
stop switch for tunnel
electric fans,
IP66 - > IK10
400C for 120
Rated Frequency Rated Poles Palazzoli Pack
current (Hz) voltage Code Q.ty
(A) (V)
63
50-60 690 3P+=
151880 1
125 151881 1
Characteristics:
11/8 cable gland for
tightening cables
22mm 26mm.
TUNNEL54 SERIES
Plugs for gallery
electric fans,
IP66 - > IK10
400C for 120
Characteristics:
3-pole terminal block with
brass conductor bars and
terminals to prevent
loosening with double
screws in brass fixed to a
ceramic base. 2 IP68 cable
glands in nickel-plated brass
with ISO thread with metric
pitch with radial tightening of
the cable. M6 type external
and internal earth terminal.
Complementary items:
Fastening brackets
on page 13.
On request:
stainless steel enclosure.
TUNNEL54 SERIES
Bar enclosures for power
supply lines for tunnel
electric fans,
IP66 - > IK10
400C for 120
850C for 90
Line Terminal External Line cable Palazzoli Pack
cable Block dimensions glands Code Q.ty
sections
3x10mm
2
M40
3x16mm
2
3x25mm
2
185x185x105
(19-28mm)
151553 1
3x25mm
2
M40
3x35mm
2
3x40mm
2
increased 151564 1
(22-32mm)
3x50mm
2
252x185x152 M50
151575 1
(32-38mm)
3x70mmq
M63
151585 1 3x70mm
2
(37-44mm)
Rated Frequency Rated Poles Palazzoli Pack
current (Hz) voltage Code Q.ty
(A) (V)
63
50-60 690 3P+=
151890 1
125 151891 1
fire proof
page 8
fire proof
page 8
Technical data
pages 1415
Dimensions
page 15
10
Systems
for tunnels
LIGHTING SYSTEMS
Projectors with symmetric
and asymmetric tunnel reflector
Equipment:
M25 brass cable gland.
Stainless steel brackets for wall
or roof installation.
Characteristics:
AISI 316L stainless steel body,
tempered glass diffuser 6mm
thick.Diffuser fall-prevention
system. Terminal block with
sectionable multipole safety
fuse, male-female.
Ultra-polished aluminium
reflector.
Uses:
Suitable for lighting lanes and
recesses, railways and tunnels.
TUNNEL54 SERIES
Tunnel projectors in
AISI 316L stainless
steel, glass diffuser with
symmetric aluminium
reflector and with
electromagnetic supply
unit, IP66 - Class II
Power Optics Lampholder Palazzoli Pack
(W) and lamp type Code Q.ty
1x18
2x18
1x36
2x36
1
1
1
1
152101
152102
152201
152202
G13 T8 Symmetrical
Power Optics Lampholder Palazzoli Pack
(W) and lamp type Code Q.ty
1x18
2x18
1x36
2x36
1x54
2x54
1
1
1
1
1
1
152131
152132
152231
152232
152961
152962
G13 T8
G5 T5
Symmetrical
TUNNEL54 SERIES
Tunnel projectors in AISI 316L
stainless steel, glass diffuser
with symmetric aluminium
reflector and with
electromagnetic supply unit,
IP66 - Class II
Equipment:
M25 brass cable gland.
Stainless steel brackets for
wall or roof installation.
Characteristics:
AISI 316L stainless steel
body, tempered glass diffuser
6mm thick.
Diffuser fall-prevention
system. Terminal block with
sectionable multipole safety
fuse, male-female.
Ultra-polished aluminium
reflector.
Uses:
Suitable for lighting lanes
and recesses, railways and
tunnels.
TUNNEL54 SERIES
Tunnel projectors in AISI 316L
stainless steel, glass diffuser
with symmetric aluminium
reflector and with
electromagnetic supply unit,
IP66 - Class II
Power Optics Lampholder Palazzoli Pack
(W) and lamp type Code Q.ty
1x18
2x18
1x36
2x36
1
1
1
1
153101
153102
153201
153202
G13 T8 Asymmetrical
Power Optics Lampholder Palazzoli Pack
(W) and lamp type Code Q.ty
1x18
2x18
1x36
2x36
1x54
2x54
1
1
1
1
1
1
153131
153132
153231
153232
153961
153962
G13 T8
G5 T5
Asymmetrical
TUNNEL54 SERIES
Tunnel projectors in AISI 316L
stainless steel, glass diffuser
with symmetric aluminium
reflector and with
electromagnetic supply unit,
IP66 - Class II
cable gland
M25 brass
symmetrical reflector
stainless
steel
glass
1 entry
asymmetric reflector
protection
with fuse
Technical data
pages 1415
Dimensions
page 15
Systems for tunnels
11
LIGHTING SYSTEMS
Enclosures for single-pole cables
for tunnel projectors
Characteristics:
2-pole terminal block with
brass conductor bars and
terminals to prevent
loosening with double
screws in brass fixed to a
ceramic base.
IP68 cable gland in
nickel-plated brass with ISO
thread with metric pitch with
radial tightening of the
cable. M6 type external and
internal earth terminal.
Protection of the supply
phase of the lighting body
through the E14-D01
ceramic fuseholder base
complete with fuses.
The fuse based is
precabled at the spur.
Spur with M25 cable gland
(9-17mm clamp).
Complementary items:
fastening brackets on page
13.
TUNNEL54 SERIES
Enclosures for through line
for single-pole cables for
gallery projectors, spur with
cable gland, IP66 - > IK10
400C for 120
850C for 90
Line cable Terminal External Line cable Palazzoli Pack
sections board size (mm) glands Code Q.ty
2x (1x4mm
2
)
2x(1x6mm
2
)
2x (1x10mm
2
)
2x(1x16mm
2
)
2x (1x25mm
2
)
2x(1x35mm
2
)
2x (1x50mm
2
)
2x(1x70mm
2
)
M16
(4,5-10mm)
M20
(7-13mm)
M25
(9-17mm)
M32
(11-21mm)
2x6mm
2
2x16mm
2
2x40mm
2
2x70mm
2
1
1
1
1
151011
151022
151034
151045
185x185x105
185x252x152
252x315x193
TUNNEL54 SERIES
Containers for line bottom
for single-pole cables for
tunnel projectors, spur with
cable gland IP66 - > IK10
400C for 120
850C for 90
Line cable Terminal External Line cable Palazzoli Pack
sections board size (mm) glands Code Q.ty
2x (1x4mm
2
)
2x(1x6mm
2
)
2x (1x10mm
2
)
2x(1x16mm
2
)
2x (1x25mm
2
)
2x(1x35mm
2
)
2x (1x50mm
2
)
2x(1x70mm
2
)
M16
(4,5-10mm)
M20
(7-13mm)
M25
(9-17mm)
M32
(11-21mm)
2x6mm
2
2x16mm
2
2x40mm
2
2x70mm
2
1
1
1
1
151111
151122
151134
151145
185x185x105
185x252x152
252x315x193
M6 type external and internal
earth terminal. Protection of
the supply phase of the
lighting body through the
E14-D01 ceramic fuseholder
base complete with fuses.
The fuse based is precabled
at the spur. Spur with
socket-outlet 16A - 1P+N=.
Resistance at 400C x 120
and 850C x 90applies to
enclosure.
Complementary items:
fastening brackets on page
301. 2P+= 16A IP67 plug on
page 13.
Characteristics:
2-pole terminal block with
brass conductor bars and
terminals to prevent
loosening with double screws
in brass fixed to a ceramic
base. IP68 cable glands in
nickel-plated brass with ISO
thread with metric pitch with
radial tightening of the cable.
TUNNEL54 SERIES
Enclosures for through line
for single-pole cables for
gallery projectors, spur with
cable gland, IP66 - > IK10
400C for 120
850C for 90
Line cable Terminal External Line cable Palazzoli Pack
sections board size (mm) glands Code Q.ty
2x (1x4mm
2
)
2x(1x6mm
2
)
2x (1x10mm
2
)
2x(1x16mm
2
)
2x (1x25mm
2
)
2x(1x35mm
2
)
2x (1x50mm
2
)
2x(1x70mm
2
)
M16
(4,5-10mm)
M20
(7-13mm)
M25
(9-17mm)
M32
(11-21mm)
2x6mm
2
2x16mm
2
2x40mm
2
2x70mm
2
1
1
1
1
151311
151322
151334
151345
185x185x105
185x252x152
252x315x193
fire proof
page 8
Technical data
pages 1415
Dimensions
page 15
12
Systems
for tunnels
LIGHTING SYSTEMS
Enclosures for multipole
cables for tunnel projectors
Characteristics:
4-pole terminal block with
brass conductor bars and
terminals to prevent
loosening with double
screws in brass fixed to a
ceramic base. IP68 cable
gland in nickel-plated brass
with ISO thread with metric
pitch with radial tightening
of the cable. M6 type
external and internal earth
terminal. Protection of the
supply phase of the lighting
body through the E14-D01
ceramic fuseholder base
complete with fuses. The
fuse based is precabled at
the spur. Spur with M25
cable gland (9-17mm
clamp).
TUNNEL54 SERIES
Enclosures for through line
for multipole cables for
gallery projectors, spur
with cable gland
IP66 - > IK10
400C for 120
850C for 90
Line cable Terminal External Line cable Palazzoli Pack
sections board size (mm) glands Code Q.ty
4x4mm
2
/
3G (2F+=) 4mm
2
4x6mm
2
/
3G (2F+=) 6mm
2
4x10mm
2
/
3G (2F+=) 10mm
2
4x16mm
2
/
3G (2F+=) 16mm
2
4x25mm
2
/
3G (2F+=) 25mm
2
4x35mm
2
/
3G (2F+=) 35mm
2
3x50mm
2
+25mm
2
/
3G (2F+=) 50mm
2
3x70mm
2
+35mm
2
3G (2F+=) 70mm
2
M32
(11-21)
M40
(19-28)
M40
increased
(22-32)
M50
(32-38)
M63 (37-44)
4x6mm
2
4x16mm
2
4x40mm
2
4x70mm
2
151241
151242
151252
151264
151275
151285
1
1
1
1
1
1
185x252x152
252x315x193
Characteristics:
Spur with socket-outlet
16A - 2P+=.
Resistance at 400C x 120
and 850C x 90applies to
enclosure.
Complementary items:
fastening brackets
on page 301.
2P+=16A IP67 plug
on page 13.
TUNNEL54 SERIES
Enclosures for through line
for multi-pole cables for
gallery projectors, spur
with cable gland
IP66 - > IK10
400C for 120
850C for 90
Line cable Terminal External Line cable Palazzoli Pack
sections board size (mm) glands Code Q.ty
4x4mm
2
/
3G (2F+=) 4mm
2
4x6mm
2
/
3G (2F+=) 6mm
2
4x10mm
2
/
3G (2F+=) 10mm
2
4x16mm
2
/
3G (2F+=) 16mm
2
4x25mm
2
/
3G (2F+=) 25mm
2
4x35mm
2
/
3G (2F+=) 35mm
2
3x50mm
2
+25mm
2
/
3G (2F+=) 50mm
2
3x70mm
2
+35mm
2
3G (2F+=) 70mm
2
M32
(11-21)
M40
(19-28)
M40
increased
(22-32)
M50
(32-38)
4x6mm
2
4x16mm
2
4x40mm
2
4x70mm
2
151441
151442
151452
151464
151475
151485
1
1
1
1
1
1
185x252x152
252x315x193
Characteristics:
4-pole terminal block with
brass conductor bars and
terminals to prevent
loosening with double
screws in brass fixed to a
ceramic base. 2 IP68 cable
glands in nickel-plated brass
with ISO thread with metric
pitch with radial tightening of
the cable. M6 type external
and internal earth terminal.
On request:
stainless steel enclosure.
TUNNEL54 SERIES
Bar enclosures for
power supply lines for
tunnel projectors
IP66 - > IK10
400C for 120
850C for 90
Line cable Terminal External Line cable Palazzoli Pack
sections board size (mm) glands Code Q.ty
4x4mm
2
/
3G (2F+=) 4mm
2
4x6mm
2
/
3G (2F+=) 6mm
2
4x10mm
2
/
3G (2F+=) 10mm
2
4x16mm
2
/
3G (2F+=) 16mm
2
4x25mm
2
/
3G (2F+=) 25mm
2
4x35mm
2
/
3G (2F+=) 35mm
2
3x50mm
2
+25mm
2
/
3G (2F+=) 50mm
2
3x70mm
2
+35mm
2
3G (2F+=) 70mm
2
M32
(11-21)
M40
(19-28)
M40
increased
(22-32)
M50
(32-38)
4x6mm
2
4x16mm
2
4x40mm
2
4x70mm
2
151641
151642
151652
151664
151675
151685
1
1
1
1
1
1
252x185x152
315x252x193
fire proof
page 8
M63 (37-44)
M63 (37-44)
Technical data
pages 1415
Dimensions
page 15
Systems for tunnels
13
Technical accessories for
interlocked socket-outlets,
for electric fans
Characteristics:
cable gland in nickel-plated
brass with ISO thread with
metric pitch with radial
tightening of the cable.
Complementary items:
socket-outlets for electric
fans on page 9.
TUNNEL54 SERIES
Raised closing flanges in
aluminium alloy with
brass cable gland
IP67 - > IK10
400C for 120
850C for 90
Uses:
they close unused windows.
They enable large cables or
conduits to be inserted into
the enclosure.
Complementary items:
nickel-plated brass cable
glands on page 9.
ALUPRES SERIES
Raised closing flanges in
aluminium alloy
IP67 - > IK10
400C for 120
850C for 90
Per finestre tipo Overhang Palazzoli Pack
(mm) Code Q.ty
F5 80 540065 1
For windows type Line cable glands Palazzoli Pack
Code Q.ty
M40 (1928) 151930 1
F5
M40 increased (2232) 151931 1
M50 (3238) 151932 1
M63 (3744) 151933 1
Characteristics:
complete with adjustable
roof fitting, 50x30mm
section and socket-outlet
fixing screws.
Equipment:
fastening screws
for enclosures.
TUNNEL54 SERIES
Pair of supports for fixing
socket-outlets to roof with
RCCB for electric fans
Material Palazzoli Pack
Code Q.ty
AISI 316L stainless steel 151900 1
TUNNEL54 SERIES
Pair of supports
for fixing tunnel
enclosures
Material For boxes with Palazzoli Pack
external dimensions Code Q.ty
(mm)
185x185 / 252x185 151901 1
AISI 316L stainless steel 185x252 / 315x252 151902 1
252x315 151903 1
fire proof
page 8
14
Systems
for tunnels
Resistance to fire Resistance to Housings Terminals
excess heat
CEI EN50200 ANAS CEI EN50298 CEI EN 60947-7-1
CEI EN 50362 08-09-99 CEI 17-71 CEI 17-48
CEI 20-36 Prot. 7735 CEI 23-48
Reference
standards
General
features
Due to the complexity of the problems involved, electric installations in tunnels represent particular applications that, for the
Electrical installations in tunnels constitute, an view of the complex problems that they imply, particular applications that
presently do not find correspondence an specific CEI, CENELEC or IEC normatives.
The tragic accident in the Mont Blanc tunnel gave rise to some national measures (Ministerial Decree 6-12-99 and Ministerial
Decree 5-6-2001) which recently emerged in a EU context in the 2004/54/EC Directive which lays down the minimum safety
requisites in road tunnels. However, as far as electric circuits are concerned, only guidelines can be referved to from the
current legislation, translated into some general regulations in the ANAS (National Road Board) circular of 08-09-99:
- all tunnels that are longer than 125m must have lighting;
- tunnels longer than 1000m must also have artificial ventilation;
- as far as the safety measures for fire prevention are concerned, the materials used must be fire retardant and must not emit
toxic gases; for the equipments such as ventilators and the armatures of the lighting system, a resistance to temperatures of
400C for at least 90 minutes is required.
The Palazzoli proposal against the risks of fire
The main problem, solved with Palazzoli products for tunnels, is that of preventing the fire, affecting the connections, from
causing the interruption of the main lines due to:
- interruption of the electrical continuity due to the terminal burning;
- interruption of the electrical continuity due to loosening of the clamping screws caused by the enormous temperature increases;
- a short circuit between the phases or between these and the earth, due to the live parts moving caused by damage to the
insulator which keeps the conducting parts of the terminals in place;
- a short circuit to earth caused by contact with the metal parts of the anchoring and containment, due to the collapse of the
insulator which forms the base of the terminal.
These problems have been solved using very thick metal casings, anti-loosening clamping terminals, bases made from
fireproof ceramic material, appropriately spaced and insulated fixing systems and brass stepped glands.
To be effective, these features require coordination with appropriately fire-resistant cables, namely:
- insulated in magnesium oxide, meeting IEC EN 60702-2 standard;
- made of special elastomer with fireproof protective sheaths based on G 10 reticulated mixes or G4, EI2 silicones, meeting
the IEC 20-45 standard.
Junctions made with the Palazzoli tunnel components are as fire-resistant as the aforementioned cables and are tested as
shown by the test carried out at the IMQ laboratory, applying the procedure laid down by the IEC EN 50200 standard, directing
the unified flame, calibrated at 850C (+ 40C tolerance) by means of thermocouples, on the boxes or on the connectors.
Resistance up to 400C for 90 minutes as required by the ANAS circular (test carried out at the INTEK laboratory with a
positive outcome for more than 120 minutes) is fully guaranteed.
The junction resists the flame for a period of time of not less than that foreseen for the cable, ensuring that there are no
interruptions or short circuits between the phases and to the earth. Flame at 830 calibrated with thermocouples, in
compliance with the IEC EN 50200 test procedure.
THE STANDARDS:
Flame
830C
Flame
830C
230/400V
15
Systems for tunnels
Specifications
The metal casings of the boxes and connectors with flat plugs are made from very thick pressure die-cast UNI 5076 light alloy with a high
aluminium content. The special surface treatments, preceded by chromium coating guarantee inalterability, both in very damp environments,
typical of tunnels, and against the corrosive dusts generated by road traffic.
The IP66 rating fully ensures protection against dripping water, streaming water and cleaning with jets of water.
Protection against shock amply exceeds the IK10 (20J) degree which is the maximum laid down by current standards.
The fixing eyelets to the wall, outside the boxes, allow tightening the screws in the case of loosening of the plugs, without accessing the electric
parts; this simple but functional system is also suitable for fixing to conducts and gangways and any metal or masonry structure.
The thermal conductivity of the alloy, together with the great thicknesses, helps disperse the heat produced by the flames encompassing the casing,
protecting the junction.
The junctions
The junctions in the boxes are made by screw terminals with a brass body mounted on bars insulated by ceramic supports; this way a rigid system
is produced which can maintain the distances of insulation even in the event of thermal shock; fixing the ceramic block to the base of the box by
means of metal inserts, at a good distance from the live parts, avoids the contact towards earth under the action of the flames. The screw clampings
on the brass body guarantee against loosening due to corrosion in a damp environment and to fast thermal variations which occur during a fire.
The unions
The unions between boxes and cables are made by means of nickel-plated brass cable glands, metric threaded and with a radial type of clamping.
The use of brass avoids the cable gland representing a weak point from the point of view of resistance to heat and flames.
Electrical functions and features
The functions of the products for tunnels are those typical of junction, shunting and termination of unipolar or multipolar cables with a cross-
section of between 1.5 and 70 mm
2
. The characteristics of the terminals allow performances up to the levels shown in the table.
METAL CASINGS:
Characteristics of the connecting terminals of the cables in the boxes
Rated cross-section mm
2
Rated thermal current I
th
(A)
Short duration rated current I
cw
(kA)
Tearing resistance (N)
Minimum cross-section that can be clamped (mm
2
)
Maximum cross-section that can be clamped (stiff conductor) mm
2
Maximum cross-section that can be clamped (flexible conductor) mm
2
Rated voltage of insulation Ui (V)
6 10 16 25 35 50 70
41 57 76 101 125 192 232
0,72 1,2 1,92 3 4,2 6 8,4
80 90 100 135 190 230 285
1 4 6 10 16 16 16
6 10 16 25 35 50 70
4 6 10 16 25 35 50
500
18 W 36/54 W
25
(fixing)
(
f
ix
in
g
)
*external earth screw
F
(b
u
tto
n
h
o
le
)
185 185 105 171 171 6 M6
252 185 152 236 169 7 M6
185 252 152 169 236 7 M6
252 315 193 224 300 9 M10
315 252 193 300 224 9 M10
A B C D E F *screw
(mm) (mm) (mm) (mm) (mm) (mm)
Plugs and socket-outlets for tunnels Tunnel projectors
Enclosures for tunnels
Palazzoli S.p.A.
Via F. Palazzoli, 31 - 25128 Brescia, Italia
Tel. +39 030 2015.1 - Fax +39 030 2015.258
export@palazzoli.com
www.palazzoli.com
5
5
2
3
3
/
0
7
A20 Messina - Palermo
Applicable References
GALLERIA PIANA
S. Stefano di Camastra
LIGHTING SYSTEM
Unipolar, multipolar derivations and
line breakers for flood light lines
Nuova Aurelia
GALLERIA MARINASCO
La Spezia
VENTILATION SYSTEM
Interlocked Sockets, plugs and line
breaker enclosures to power the
electrical ventilation system
S.S. 612
GALLERIA CEMBRA
Trento
AUXILIARY SERVICE SYSTEMS
Distribution boards with interlocked
sockets for niches, by-passes and
lay-bys