VIPA MKII Installation Manual V1.6

Tunnel Sensors Ltd
www.tunnelsensors.com
VIPA MkII – Visibility Monitor for Tunnels
Installation Manual V1.6
Tunnel Sensors Ltd – Furlong House, Crowfield, Brackley, Northamptonshire, NN13 5TW United Kingdom
© Tunnel Sensors Ltd 2014
All technical details and specifications are subject to change without notice
VIPA MkII – Visibility Monitor for Tunnels - Installation Manual
Contents
Contents........................................................................................................... 1
Warnings .......................................................................................................... 2
General Warnings ........................................................................................ 3
Product Overview............................................................................................. 5
Physical Installation of the VIPA ...................................................................... 9

Choosing a location for the TX/RX ............................................................... 9
Fixing the TX/RX to the wall ....................................................................... 11
Installing the interconnecting cable (RX to TX)........................................... 16
Electrical Installation ...................................................................................... 17

Installation Wiring Diagram......................................................................... 18
Reference ...................................................................................................... 20
TX & RX Connectors .................................................................................. 20
RX Connector Locations............................................................................. 20
TX Connector Locations ............................................................................. 22
Physical Installation of the TSCU ................................................................... 23
Revision Control............................................................................................. 25
1
Warnings
Throughout the manual the following symbols are used to highlight the
potential dangers when installing, operating and servicing the instruments.
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 optics and 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 any instrument. “Hot plugging” as this is known,
may damage the electronics and require a circuit board to be
replaced. 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
3
output tolerance of the power supply. The stated voltage supply

is that at the point of connection at the instrument.
 The cables to and from the instrument 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.
 The ferrite tubes supplied should be fitted on all cables where

they connect to the instrument enclosures.
 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 VIPA tunnel monitor measures visible opacity to determine the visibility
within the tunnel. The measurements can be used as part of an air quality
management system within a tunnel or other confined space.
The VIPA consists of a Transmitter head (TX) and Receiver head (RX) which
are mounted on the tunnel wall with a nominal separation of 10m. The TX and
RX are connected with a single interconnecting cable which carries power and
signals between the two heads.
The TX emits a green optical beam for the visibility measurement, which is
received by the RX and then conditioned and processed on an internal optical
bench.
The visibility levels are determined using the standard light transmission
obscuration technique.
The VIPA is an intelligent analyser that can operate as a “stand-alone”

monitor without the need for a control unit. In this configuration all SCADA
interface connections are made directly to the RX on the tunnel wall. Set-up
and control of the instrument is performed with the use of the utility software
package installed on a PC (usually a laptop), which can be temporarily
connected to the RX.
The VIPA can also be paired with a TSCU (Tunnel Sensors Control Unit); this
is a remotely located control unit with a display, keypad and full range of
interface capabilities to match the RX. The TSCU is an optional extra and is
not included with a standard VIPA, but can be ordered separately.
If a TSCU is used, it is connected directly to the RX via a single umbilical

cable which carries power and communications (RS485), allowing the RX to
operate with just a single external cable connection. Because the TSCU has
all the same interface abilities as the RX, interface connections can be made
directly to the TSCU (which can be positioned at a convenient accessible
location) and/or to the RX. This versatility offers the flexibility to accommodate
a wide range of wiring schemes.
Both the VIPA and the optional TSCU offer a variety of industry standard
interface options. Scalable analogue outputs are available in the form of
isolated 0, 2 or 4-20mA current loops. Digital outputs are available in the form
of relay contacts for service alarm (data valid) and/or programmable level
alarm.
5
Serial communications channels are available in both the RX and the optional
TSCU. RS485 is available as standard. Please enquire with us directly if you
have any specific requirements for serial communications.
As a stand-alone instrument the VIPA requires a 1A +24VDC power supply,

connected to the RX. However, if the VIPA is installed with a TSCU, the same
power supply can be connected at the TSCU instead, and will be relayed to
the VIPA via the umbilical cable, provided the cable is less than 100m long. If
the umbilical cable is longer than 100m then two separate power supplies will
be required, one for the RX, and one for the TSCU.
The following drawing shows the general configuration for stand-alone

operation, followed by the general configuration with a TSCU.
6
7
8
Physical Installation of the VIPA
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 optics and

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.
Physical installation consists of:
1. Choosing a location for the TX/RX.

2. Fixing the TX/RX to the wall.
3. Installing the interconnecting cable (no wiring connections at this stage).
Choosing a location for the TX/RX
Points for consideration:
 Pre-planned monitoring positions

 Accessibility and traffic clearance
 Sunlight and other intense light sources
 Water and road spray
 Temperature
 Cable routes
 Protective Earthing
 The basic position of monitoring points along the tunnel bore will
usually be dictated by plans drawn up by ventilation design engineers.
9
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 and traffic clearance should be considered carefully when

locating the VIPA.
The VIPA are a protrusion into the bore which will inevitably reduce the
clearance between it and the traffic. It may be that the VIPA reduces
the lateral clearance, headroom, or both, so ensure that clearance
between the heads and the traffic flow has been calculated carefully
before settling on an installation position.
Human access will be required occasionally, so consider means and

ease of access for future maintenance operatives.
The VIPA has been designed to be mounted on the tunnel wall, and
the ideal height is about 3.5m, 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 an ordinary
ladder. If possible avoid mounting the heads at excessive height, on
the roof of the tunnel, or over traffic.
 Sunlight may seem like an unusual consideration in a tunnel, but

instruments located near the entrance and exit of the tunnel can
become exposed to direct sunlight.
It is essential that the instrument is installed in such a way that sunlight

(or any other intense light source) cannot, at any time of the day or
year, shine into the sight tube of the RX head directly and fall onto the
RX optics. If an intense light source, in particular sunlight, falls directly
onto the RX optics, it may cause the VIPA measurement circuits to
become temporarily saturated and prevent the instrument from making
proper measurements.
 Sometimes there may be regulations governing light emissions within

the tunnel; in particular they may prohibit any light source facing the
on-coming traffic flow. The logic behind this requirement is that any
light source facing the traffic may momentarily distract a driver and
cause an accident.
The VIPA emits a green light source from the TX optics. It is unusual to
see this light once the instrument is mounted on a tunnel wall, however
where regulations prohibit light emissions facing the on-coming traffic
flow, the TX must be mounted in such a way that it is pointing in the
same direction as the traffic flow.
10
 Choose a location that is not affected by water; in particular avoid

locations where water is seeping out of, or over, the tunnel wall.
Road spray can cause interference with the instrument’s optical beam,
which may result in poor measurements, and it can also be deposited
on the surface of the optics, which again can cause poor
measurements. Therefore, it is advisable to choose a location that is
unlikely to be affected by road spray.
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 +55°C.
 The VIPA will require power and interface connections. The route that
the cables will have to take to reach the TX & RX should be planned
carefully in advance and may well have an influence on the location
ultimately chosen for the VIPA.
 Protective Earthing is essential, not just as a safety precaution, but also

to maintain the instruments compliance with European safety directives
and CE marking.
Both the TX and RX have a Protective Earth Bonding Point (an M5

stud) on the outside of the main enclosure. A heavy duty earth cable,
with a proper crimped eyelet fitting, should be attached to this stud and
connected to an electrically verified local Earth.
Proper connection to a local Earth potential should be given

consideration when choosing a location for the VIPA.
Fixing the TX/RX to the wall
The TX/RX heads are mounted to the wall using a mounting bracket with
three holes in each bracket. The mounting holes/slots are designed to be
secured with M10 wall bolts.
The brackets are supplied loose (i.e. not attached to the TX/RX heads), and it
is strongly recommended that the brackets are fixed to the wall before
attaching the TX/RX heads to the brackets.
Each bracket has a pivot point which allows vertical angular adjustment of the
head.
The heads are suspended underneath the brackets and secured with the M10
bolts provided. Please note that it is absolutely vital that the bolts fixing the
11
heads to the brackets are fitted with both the flat and spring washers
provided.
Site tubes are provided and are supplied with gaskets. The gasket is adhesive
backed and must be adhered to the TX and RX heads.
The following pages detail the dimensions and fixing requirements for the
VIPA.
12
13
14
The following diagram shows good and poor alignment of the TX & RX.
15
Installing the interconnecting cable (RX to TX)
The VIPA is supplied with a 12m length of LSZH cable for connecting
between the RX and TX. The cable comes with pre-wired connectors at each
end.
The VIPA cables 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.
Wiring details are covered in the electrical installation section.
16
Electrical Installation
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 optics and

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 any instrument. “Hot
plugging” as this is known, may damage the
electronics and require a circuit board to be
replaced. This is NOT covered under warranty.
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.
17
Installation Wiring Diagram
The following page shows a complete installation wiring diagram.
This diagram includes details of common interface wiring, but not all these
connections are essential for functional operation.
Note: The minimum requirement for functional operation of a VIPA is a

+24Vdc power supply and connection of the TX/RX interconnection cable.
The instrument can be supplied with cables pre-wired with connectors as

specified at the time of ordering.
Note: due to variations in the colours of the cable cores beyond our control,
the wiring diagram does not specify what each colour core is connected to.
Instead each instrument is supplied with a printed wiring diagram (REF-031)

which details the colour coding of the cable cores.
18
19
Reference
TX & RX Connectors
With the exception of the USB, all connections to the head must be made
using cable assemblies sourced directly from Tunnel Sensors - as these
connections utilise a specialist IP68 connector system that requires making up
in the factory.
The relationship between the pin number (in the connector) and the core
colour (in the cable) is defined in a separate drawing supplied with each cable
assembly. The core colour definitions are not to be found in this manual.
Tunnel Sensors can provide duplicate drawings on request. Please quote the
cable number required (e.g. CBL-xxx-xx) which is indicated on the cable by
way of a tag/label so that we always send out the correct drawing.
RX Connector Locations
All end user electrical connections to the RX head are made using pre-made
connectors that can be supplied with each order.
The following diagram details the location and identification of all the
connections on the RX head.
20
21
TX Connector Locations
All end user electrical connections to the TX head are made using a pre-made
connector cable that is supplied with each order.
The following diagram details the location and identification of the connection
on the TX head.
22
23
Physical Installation of the TSCU
Please refer to the TSCU Installation & Operators Manual for more
information.
24
Revision Control
Revision
Version Date Revision Details Author
V1.0 20/03/2012 Original. Dominic Sheedy
V1.1 02/04/2012 Wiring diagram updated; rating for the 24vdc supply has Dominic Sheedy
been increased from 0.5A to 1A.
V1.2 29/05/2012 Product overview updated with TSCU information. Dominic Sheedy
V1.3 19/06/2012 Wiring diagram notes added/updated. Wiring connection Dominic Sheedy
information regarding connectors added/updated.
V1.4 25/06/2013 Wiring diagram updated. Dominic Sheedy
V1.5 31/07/2013 New warnings section added. Dominic Sheedy
V1.6 07/01/2014 Wiring Diagram REF-033 updated. Dominic Sheedy
All technical details and specifications are subject to change without notice
© All content copyright of Tunnel Sensors Ltd 2014
25

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Tunnel Sensors Ltd

VIPA MkII – Visibility Monitor for Tunnels

Installation Manual V1.6

© Tunnel Sensors Ltd 2014

Physical Installation of the VIPA ...................................................................... 9

Electrical Installation ...................................................................................... 17

Physical Installation of the TSCU ................................................................... 23

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 optics and electronics and

 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

output tolerance of the power supply. The stated voltage supply

 The cables to and from the instrument carry sensitive electronic

 The ferrite tubes supplied should be fitted on all cables where

 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 VIPA is an intelligent analyser that can operate as a “stand-alone”

If a TSCU is used, it is connected directly to the RX via a single umbilical

As a stand-alone instrument the VIPA requires a 1A +24VDC power supply,

The following drawing shows the general configuration for stand-alone

Physical Installation of the VIPA

All installations and connections must be made by

The instrument contains sensitive optics and

The instrument contains sensitive electronics

Physical installation consists of:

1. Choosing a location for the TX/RX.

Choosing a location for the TX/RX

Points for consideration:

 Pre-planned monitoring positions

Such plans will typically consist of monitoring points adjacent to both

 Accessibility and traffic clearance should be considered carefully when

Human access will be required occasionally, so consider means and

 Sunlight may seem like an unusual consideration in a tunnel, but

It is essential that the instrument is installed in such a way that sunlight

 Sometimes there may be regulations governing light emissions within

 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

Both the TX and RX have a Protective Earth Bonding Point (an M5

Proper connection to a local Earth potential should be given

Fixing the TX/RX to the wall

Installing the interconnecting cable (RX to TX)

Ideally any cables connecting to the instrument, or between instrument

Wiring details are covered in the electrical installation section.

All installations and connections must be made by

The instrument contains sensitive optics and

All electrical work must be carried out with the

Do not make or break electrical connections whilst

Proper connection to a local Earth potential

Installation Wiring Diagram

The following page shows a complete installation wiring diagram.

Note: The minimum requirement for functional operation of a VIPA is a

The instrument can be supplied with cables pre-wired with connectors as

Instead each instrument is supplied with a printed wiring diagram (REF-031)