ECOM Installation & Operators Manual V1.1

Tunnel Sensors
www.tunnelsensors.com
ECOM – Electrochemical CO Monitor for Tunnels
Installation & Operators Manual V1.1
Tunnel Sensors – Furlong House, Crowfield, Brackley, Northamptonshire, NN13 5TW United Kingdom
© Tunnel Sensors 2014
All technical details and specifications are subject to change without notice
ECOM – CO Monitor for Tunnels - Installation & Operators Manual
Contents
Contents........................................................................................................... 1
Warnings .......................................................................................................... 2
General Warnings ........................................................................................ 3
Product Overview............................................................................................. 5
Performance Specification............................................................................ 6
Physical Installation of the ECOM .................................................................... 7

Choosing a location for the ECOM ............................................................... 7
Fixing the ECOM to the wall ......................................................................... 9
Electrical Installation & Wiring ........................................................................ 10

Installation Wiring Diagram......................................................................... 12
ECOM Interface & Operation ......................................................................... 14

ECOM Operation ........................................................................................ 16
Analogue Output ........................................................................................ 16
Maintenance ................................................................................................. 17
Fault Messages and Trouble Shooting ......................................................... 18
Appendix A.................................................................................................... 19
Changing the Alarm Levels ........................................................................ 19
Revision Control............................................................................................ 22
1
Warnings
Throughout the manual the following symbols are used to highlight the
potential dangers when installing, operating and servicing the instrument.
Caution; Care must be taken, refer to specific

instructions.
Warning; Risk of electric shock.
Protective Conductor Terminal.
Recycle Responsibly.
Attention; observe precautions for handling electrostatic

sensitive devices.
Note: Highlights a specific instruction or operating procedure.
2
General Warnings
Each section of the manual outlines the specific warnings for that part of the
process or procedure. Below are some general guidelines that should be
followed at all times:-
 The instrument is particularly vulnerable during transportation

and manual handling. Always transport the instrument in its
original packaging and handle with utmost care.
 Prior to use, the equipment should be stored in its original

packaging in a dry and sheltered area.
 Applications vary and all installations will involve a degree of

application engineering which is the responsibility of the
customer, not Tunnel Sensors.
 All installations and connections must be made by suitably

qualified and experienced electrical / mechanical engineers with
proper regard to good practice and compliance with applicable
legislation.
 The instrument contains sensitive electronics and must be

protected from physical shock, vibration and exposure to
moisture at all times. Always handle with care, replace lids and
covers when not in use and protect from water ingress.
 The instrument contains sensitive electronics which are

vulnerable to ESD and therefore care should be taken to avoid
making contact with electronic circuit boards & components. Use
ESD handling precautions.
 All electrical work must be carried out with the power to the
instrument OFF i.e. it must be isolated from any source of
voltage. Failure to do so could result in equipment failure, injury
or death.
 Do not make or break electrical connections whilst power is

connected to the instrument. “Hot plugging” as this is known,
may damage the electronics. This is NOT covered under warranty.
 Always calculate the potential voltage drop when specifying the

type / length of any DC power cable, taking care to allow for the
output tolerance of the power supply. The stated voltage supply
is that at the point of connection at the instrument.
3
 The cables to and from the instrument may carry sensitive

electronic signals which can be affected by RFI and EMI, so care
should be taken to run the cables away from high voltage power
cables, high frequency signal cables, or switch gear cabling.
Ideally any cables connecting to the instrument, or between
instrument components, will follow an independent route and will
not be installed in bundles or cable trays with other cabling.
 Proper connection to a local Earth potential should be given

consideration when choosing a location for the instrument
components. Protective Earthing is essential, not just as a safety
precaution, but also to maintain the instruments compliance with
European safety directives and CE marking.
 A Warranty Certificate is provided with each order. Failure to

follow the procedures outlined in this manual, unless specifically
instructed to do otherwise, could invalidate the warranty.
 Read the manual in full before proceeding. If in doubt contact

your local distributor or Tunnel Sensors direct.
4
Product Overview
The ECOM tunnel monitor measures the concentration of Carbon Monoxide

(CO) in tunnel atmospheres. This measurement can be used as part of an air
quality management system within a tunnel or other confined space.
The ECOM is a fixed sensor that consists of a Sender Unit and a replaceable,
plug in, Sensor Module. The Sensor Module contains the gas sensor and
stores all the necessary data about its type identification, sensing range and
specific calibration. This data is automatically recognised by the Sender Unit
when the module is plugged into the module bay. The Sensor Module is pre-
calibrated so can be substituted at any time by a replacement module.
The level of CO is detected within the Sensor Module using an

electrochemical gas sensor. This sensor combines good sensitivity at low gas
concentrations with high range capability and excellent stability. A diffusion
barrier is used to control the air getting to the sensor, as such the instrument
is designed to be located directly within the tunnel atmosphere.
The span and zero levels of electrochemical cells can slowly drift with time,
dependent upon monitoring conditions. To ensure continued measurement
accuracy the Sensor Modules should be replaced, or recalibrated every 6 to
12 months.
The ECOM is designed to be a “stand-alone” monitor. The Sender Unit

requires a 1A +24Vdc power supply. It has a LCD which displays the
measured gas concentration, as well as any alarm thresholds and faults. The
Sender Unit also provides a 4 to 20mA analogue output of the gas
concentration for direct connection to a separate control system.
5
Performance Specification
CO Measurement Range 0 to 300ppm

Accuracy ±2%
Response Time (T90) 40s
Turn-on Time (stabilisation time) 30s
Supply Voltage 24Vdc (±3V)
Current Consumption 50mA
Operating Temperature Range -20°C to +50°C
Humidity (non condensing) 15 to 90%
Ambient Pressure 800 to 1100 mBar
Ingress Protection IP66
Signal Output 4 to 20mA
Table 1: General Specification
The gas sensor in the Sensor Module is designed to respond only to CO gas.
The sensitivity of the Sensor Module can be affected by interfering gasses,
but only at concentration levels much higher than present in a road or rail
tunnel. Steam laden atmospheres and condensation can reduce the
measurement sensitivity.
6
Physical Installation of the ECOM
All installations and connections must be made by

suitably qualified and experienced electrical /
mechanical engineers with proper regard to good
practice and compliance with applicable
legislation.
The instrument contains sensitive electronics and

must be protected from physical shock, vibration
and exposure to moisture at all times. Always
handle with care, replace lids and covers when not
in use and protect from water ingress.
The instrument contains sensitive electronics

which are vulnerable to ESD and therefore care
should be taken to avoid making contact with
electronic circuit boards & components. Use ESD
handling precautions.
Choosing a location for the ECOM
Each installation needs to be considered in its own right, with reference to

safety authorities and in compliance with mandatory local safety regulations.
The sensor must be operated in accordance with the Installation and

Operating Data to maintain safety, reliability and to preserve safety integrity
where applicable.
Points for consideration:
 Pre-planned monitoring positions

 Accessibility
 Water and road spray
 Temperature
 Cable routes
 Protective Earthing
7
 The basic position of monitoring points along the tunnel bore will
usually be dictated by plans drawn up by ventilation design engineers.
Such plans will typically consist of monitoring points adjacent to both

the entrance, and the exit of the tunnel bore (at least 50-100m inside),
and a number of equally spaced monitoring points in-between. The
frequency of intermediate measurement points will usually be between
200m and 500m, and may be dictated by local or national regulations.
 Accessibility should be considered carefully when locating the

instrument.
Human access will be required occasionally, so consider means and

ease of access for future maintenance operatives.
The ECOM has been designed to be mounted on the tunnel wall. The
ideal height is about 3.5m, as this is high enough to be clear of road
spray, direct exhaust gas, and (in the case of road tunnels) cars, but
still low enough to be accessed by a service engineer with just an
ordinary ladder. If possible avoid mounting the ECOM at excessive
height, on the roof of the tunnel, or over traffic.
 Choose a location that is not affected by water; in particular avoid

locations where water is seeping out of, or over, the tunnel wall.
Locations that are more likely to suffer from road spray problems are
the tunnel entrance/exit, and any location where standing water may
gather on the road, for instance at a low point in the tunnel.
 The instrument must be located at a position that will always have an

ambient temperature in the range -20°C to +50°C.
 The ECOM will require power and interface connections, all of which
will involve wiring connections to be made inside the ECOM. The route
that cables will have to take to reach the ECOM should be planned
carefully in advance and may well have an influence on the location
ultimately chosen for the ECOM.
 Protective Earthing is essential, not just as a safety precaution, but also

to maintain the instruments compliance with European safety directives
and CE marking.
Proper connection to a local Earth potential should be given

consideration when choosing a location for the ECOM.
8
Fixing the ECOM to the wall
The ECOM can be mounted directly to the tunnel wall via two M6 bolts, see
details below. The two fixing holes are accessible by removing the instrument
cover. If possible the instrument should be mounted vertically, as illustrated
below.
Figure 1: ECOM Dimensions
9
Electrical Installation & Wiring
All installations and connections must be made by

suitably qualified and experienced electrical /
mechanical engineers with proper regard to good
practice and compliance with applicable legislation.
The instrument contains sensitive electronics and

must be protected from physical shock, vibration
and exposure to moisture at all times. Always
handle with care, replace lids and covers when not
in use and protect from water ingress.
All electrical work must be carried out with the

power to the instrument OFF i.e. it must be
isolated from any source of voltage. Failure to do
so could result in equipment failure, injury or
death.
Do not make or break electrical connections whilst

power is connected to the instrument. “Hot
plugging” as this is known, may damage the
electronics. This is NOT covered under warranty.
Warning: If long cable runs are used, ensure that

the difference in earth potential at either end of the
cable is less than +/-5V (AC or DC).
10
Proper connection to a local Earth potential should

be given consideration when choosing a location
for the instrument components. Protective Earthing
is essential, not just as a safety precaution, but
also to maintain the instruments compliance with
European safety directives and CE marking.
Note: Always calculate the potential voltage drop when specifying the
type/length of the power cable, taking care to allow for the output tolerance of
the power supply. The 24Vdc supply to the instrument must not fall below
20Vdc.
When using long cable runs it is essential to check for differences in earth
potential between the different locations and to ensure that the difference is
no more than +/-5V AC or DC.
The cable to the ECOM requires at least 4-cores, which should have core
sizes of between 0.518mm² (20AWG) and 2.08mm² (14AWG).
The cable must be screened, ideally individually screened twisted pairs with a
common drain wire, such as Belden 9873 (6 core, screened pair, 20AWG).
The overall diameter of the cable should be between 6 and 12mm.
Ideally any cable connecting to the instrument will follow an independent route
and will not be installed in bundles or cable trays with other cabling.
The cable must enter the ECOM through the cable gland. This cable gland
must be tightened onto the cable to maintain the enclosures environmental
rating.
11
Installation Wiring Diagram
To access the wiring terminal block, remove the terminal chamber safety
cover. Ensure that the cover is replaced when wiring is complete.
Figure 2: Terminal Chamber
The DC power is connected to terminals 5 and 6 and the analogue output

uses terminals 1 and 3, as illustrated in the following wiring diagram.
12
Figure 3: Wiring Diagram
13
ECOM Interface & Operation
The ECOM is setup and configured by Tunnel Sensors and does not normally
need to be adjusted. The instrument has the analogue output (4 to 20mA) set
to the range 0 to 300ppm. Two alarm values are also pre-set; a GENERAL
alarm at 30ppm and a HIGH alarm at 100ppm. These alarms produce an
alarm indication on the display, the instrument does not provide any alarm
relays.
The alarm set-points can be adjusted, if required, as described in Appendix A.
Figure 4: ECOM Controls and Indicators
14
Figure 5: ECOM Controls and Indicators
15
ECOM Operation
When power is first applied to the ECOM it will briefly show an information
display which includes the software versions. The Sender Unit will then
interrogate the Sensor Module that is fitted to identify the gas sensor and the
calibrated measuring range.
Once the auto configuration is complete, the display will step to the main
display to show the measured value of the gas concentration.
Analogue Output
Check that the output signal shown on the display corresponds with the
analogue output current received at the PLC or data logger.
16
Maintenance
The Sender Unit will not normally require maintenance or calibration.

However, it is recommended that the Gas Entry port is occasionally inspected
and kept clear of any debris of blockages.
The Sender Unit is a very reliable, sealed instrument and as such has no
replaceable or repairable parts. Damaged or failed Sender Units will have to
be replaced.
The Sensor Module should be changed at regular intervals to ensure

accuracy of response. Electrochemical cells contain an electrolyte that is
gradually consumed during use, resulting in drift in the zero and span levels.
The rate of drift depends on the operating conditions of the sensor (e.g.
temperature, humidity, gas levels). It is recommended that the Sensor Module
is replaced every 6 to 12 months.
The Sensor Modules are pre-calibrated and can be very simply replaced.
There is no need to power down the Sender Unit. Open the cover by undoing
the four screws to reveal the Sensor Module. Unplug the old module and
replace with a new one. Replacement Sensor Modules are supplied by Tunnel
Sensors.
17
Fault Messages and Trouble Shooting
The Sender Unit of the ECOM can identify and display the following fault
conditions.
OVER-RANGE
If the measured gas concentration exceeds the maximum range of the Sensor
Module (300ppm), the ‘OVER-RANGE’ icon will be displayed (!>). When the
gas concentration reduces to within the measuring range of the sensor it will
read normally.
During this fault condition the analogue output will be above the maximum
range (20mA) and will saturate at 21mA.
MODULE NOT FITTED

If the Sensor Module is removed for longer than 10 seconds or contact with
the Sensor Module is lost a ‘MODULE NOT FITTED’ message will be
displayed.
With this fault condition the analogue output will be forced to it’s under range
value of 2mA.
18
Appendix A
Changing the Alarm Levels
The alarm level set-points are automatically pre-set to recommended default

values, however they can be adjusted.
Underneath the front cover of the ECOM are two pushbuttons, one on the left
side (LS) and one on the right side (RS).
Press the right side (RS) pushbutton on the ECOM to select the main menu,
then press the LS button to highlight ‘Module Setup’ as shown below. Press
the RS button to select it.
Press the LS button to select ‘Setpoint 1’
19
The set-point can be set to activate when the measured gas concentration is
UNDER or OVER the set-point value. Press the RS button to select
‘Activation’.
Press the RS button to change between UNDER and OVER. Press the LS
button to select SAVE or CANCEL, and the RS button to select.
Select the LEVEL option from the Setpoint 1 menu and press the RS button.
20
Press the RS button to change the value, and the LS button to select each
digit, then select SAVE or CANCEL.
Repeat for Setpoint 2 if required.
21
Revision Control
Revision
Version Date Revision Details Author
V1.0 17/02/2014 Original. Dominic Sheedy
V1.1 07/03/2014 Added Figures and updated labels on Figure 4. Dominic Sheedy
All technical details and specifications are subject to change without notice
© All content copyright of Tunnel Sensors 2014
22

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Tunnel Sensors

ECOM – Electrochemical CO Monitor for Tunnels

Installation & Operators Manual V1.1

© Tunnel Sensors 2014

Physical Installation of the ECOM .................................................................... 7

Electrical Installation & Wiring ........................................................................ 10

ECOM Interface & Operation ......................................................................... 14

Fault Messages and Trouble Shooting ......................................................... 18

Caution; Care must be taken, refer to specific

Warning; Risk of electric shock.

Protective Conductor Terminal.

Attention; observe precautions for handling electrostatic

Note: Highlights a specific instruction or operating procedure.

 The instrument is particularly vulnerable during transportation

 Prior to use, the equipment should be stored in its original

 Applications vary and all installations will involve a degree of

 All installations and connections must be made by suitably

 The instrument contains sensitive electronics and must be

 The instrument contains sensitive electronics which are

 Do not make or break electrical connections whilst power is

 Always calculate the potential voltage drop when specifying the

 The cables to and from the instrument may carry sensitive

 Proper connection to a local Earth potential should be given

 A Warranty Certificate is provided with each order. Failure to

 Read the manual in full before proceeding. If in doubt contact

The ECOM tunnel monitor measures the concentration of Carbon Monoxide

The level of CO is detected within the Sensor Module using an

The ECOM is designed to be a “stand-alone” monitor. The Sender Unit

CO Measurement Range 0 to 300ppm

Physical Installation of the ECOM

All installations and connections must be made by

The instrument contains sensitive electronics and

The instrument contains sensitive electronics

Choosing a location for the ECOM

Each installation needs to be considered in its own right, with reference to

The sensor must be operated in accordance with the Installation and

Points for consideration:

 Pre-planned monitoring positions

Such plans will typically consist of monitoring points adjacent to both

 Accessibility should be considered carefully when locating the

Human access will be required occasionally, so consider means and

 Choose a location that is not affected by water; in particular avoid

 The instrument must be located at a position that will always have an

 Protective Earthing is essential, not just as a safety precaution, but also

Proper connection to a local Earth potential should be given

Fixing the ECOM to the wall

Figure 1: ECOM Dimensions

Electrical Installation & Wiring

All installations and connections must be made by

The instrument contains sensitive electronics and

All electrical work must be carried out with the

Do not make or break electrical connections whilst

Warning: If long cable runs are used, ensure that

Proper connection to a local Earth potential should

The overall diameter of the cable should be between 6 and 12mm.

Installation Wiring Diagram

Figure 2: Terminal Chamber

The DC power is connected to terminals 5 and 6 and the analogue output

Figure 3: Wiring Diagram

ECOM Interface & Operation

The alarm set-points can be adjusted, if required, as described in Appendix A.

Figure 4: ECOM Controls and Indicators

Figure 5: ECOM Controls and Indicators

The Sender Unit will not normally require maintenance or calibration.

ECOM Installation & Operators Manual V1.1

ECOM Installation & Operators Manual V1.1