Page 1

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.

Certified

850°C - 90’

2007/08 Edition

400°C - 120’


Systems for tunnels Introduction

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:

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 PRIORITY

Axis Patrai Sofia Bucarest Portugal Portugal Spain North triangle

Europe In use (excluding Italy): 171 tunnels (all part of the Trans European Road Network) New: 95 tunnels

DEVELOPMENT PROJECTS FOR ROAD NETWORKS INCLUDED IN

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

Axis Great Britain Benelux Gdansk Vienna Ireland Great Britain

ANNEX III

OF

DECISION N째 1692/96 CE

Section Various

Start of Works 2010

Gdansk - Katowice Katowice - Brno Brno - Vienna Dublin - Larne Hule - Liverpool

2010 2010 2009 2010 2015 (chart 1)

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Legislative and regulatory framework

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: CEE (including Italy)

Italy only: Juridical regulations: Law 186/68 Ministry decree 31-3-95 Ministry decree 6-11-99 Ministry decree 5-6-2001

The laws in details

Systems Standards: CEI, UNI (See details on page 4)

Juridical regulations: Directive 2004/54/CE

Systems Standards: CEI EN, CIE, CEN (See details on page 4)

EC DIRECTIVE 2004/54/EC

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. LAW 186/68

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. M.D. MARCH 31 1995

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. M.D. DECEMBER 6 1999

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.

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Systems for tunnels

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. M.D. JUNE 5 2001

This is actually an extension of the deadline set for tunnel compliance pursuant to MD December 6 1999. THE

The Standards in details

4

ELECTRICAL AND ELECTRONIC SYSTEM

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


function for a limited period of time in the presence of fire in tunnels at temperature up to 830°C; the flameresistance 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. TECHNICAL LIGHTING

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 CARATTERISTICHE CIE GENERALI : recommendations. 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. THE

OTHER 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.

5


SYSTEMS FOR TUNNELS

TUNNEL54 Series page 9

TUNNEL54 Series page 9

Socket-outlets and plugs for electric fans

Electric fan line bar

VENTILATION SYSTEMS

GALLERIA PIANA - Messina – Palermo motorway 125A TUNNEL54 Series electric fan supply with socket-outlet and plug, certified for 400°C for 120’. System made by EUROTEL S.r.l. of Agrigento.

400°C - 120’ INTEK certified

6


TUNNEL54 Series page 10

TUNNEL54 Series page 11

TUNNEL54 Series page 12

TUNNEL54 Series page 12

Projectors for lanes and recesses

Spurs for single-pole cable

Spurs for multi-pole cable

Projector line bar

LIGHTING SYSTEMS

GALLERIA S. STEFANO DICAMASTRA (ME) Spurs to lighting bodies with enclosures of the TUNNEL54 Series, certified for 400°C for 120’ and 850°C for 90’. System installed by association of businesses: Carlo Gavazzi / Brulli / S.I.E.G.

7


Systems for tunnels

Techniques and advantages

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.

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 400°C for 120’ have been passed (A.N.A.S. circular 7735 of 8 September 1999) and at 850 °C for 90 minutes (EN 50200).

AGAINST FIRE WITHOUT COMPROMISES

400°C - 120’ INTEK certified

The TUNNEL54 interlocked socket-outlets for electric fans in the dual versions 63A and 125A ensure operation at 400°C 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 850°C for 90’.

850°C - 90’ IMQ certified

COMFORT AND SAFETY

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.

8

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.


VENTILATION SYSTEMS Socket-outlets with stop switch and plugs for tunnel electric fans

Rated current (A)

TUNNEL54 SERIES Socket-outlets with

63 125

Systems for tunnels

Frequency (Hz)

Rated voltage (V)

Poles

50-60

690

3P+=

Palazzoli Code

Pack Q.ty

151880 151881

1 1

stop switch for tunnel electric fans,

fire proof page 8

Equipment: provided with washers and screws for fixing accessories. Internal and external earth terminal. Characteristics: upper side passage with F5 window.

IP66 - > IK10 400°C for 120’

Complementary items: flanges with cable gland, closing flanges and fastening brackets on page 13.

Rated current (A)

TUNNEL54 SERIES Plugs for gallery

Frequency (Hz)

Rated voltage (V)

Poles

50-60

690

Terminal Block

3x10mm2 3x16mm2 3x25mm2

3x25mm2

3x35mm2

3x40mm2

63 125

Palazzoli Code

Pack Q.ty

3P+=

151890 151891

1 1

External dimensions

Line cable glands

Palazzoli Code

Pack Q.ty

185x185x105

M40 (19-28mm)

151553

1

151564

1

252x185x152

M40 increased (22-32mm) M50 (32-38mm) M63 (37-44mm)

151575

1

151585

1

electric fans,

Characteristics: 1”1/8 cable gland for tightening cables Ø 22mm ÷ 26mm.

IP66 - > IK10 400°C for 120’

Line cable sections

TUNNEL54 SERIES Bar enclosures for power supply lines for tunnel electric fans, IP66 - > IK10 400°C for 120’ 850°C for 90’

3x50mm2 3x70mmq 3x70mm2

fire proof page 8

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.

Technical data pages 14÷15 Dimensions page 15

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Systems for tunnels

Power (W)

TUNNEL54 SERIES Tunnel projectors in AISI 316L stainless

1x18 2x18 1x36 2x36

LIGHTING SYSTEMS Projectors with symmetric and asymmetric tunnel reflector

Optics

Symmetrical

Lampholder and lamp type

Palazzoli Code

Pack Q.ty

G13 T8

152101 152102 152201 152202

1 1 1 1

steel, glass diffuser with symmetric aluminium reflector and with electromagnetic supply stainless steel

unit, IP66 - Class II

glass

Power (W)

TUNNEL54 SERIES Tunnel projectors in AISI 316L symmetrical reflector

stainless steel, glass diffuser with symmetric aluminium reflector and with

1x18 2x18 1x36 2x36 1x54 2x54

Optics

Lampholder and lamp type

Palazzoli Code

Pack Q.ty

152131 152132 152231 152232 152961 152962

1 1 1 1 1 1

Lampholder and lamp type

Palazzoli Code

Pack Q.ty

G13 T8

153101 153102 153201 153202

1 1 1 1

G13 T8 Symmetrical G5 T5

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.

electromagnetic supply unit, 1 entry

IP66 - Class II

cable gland M25 brass Power (W)

protection with fuse

TUNNEL54 SERIES Tunnel projectors in AISI 316L stainless steel, glass diffuser

1x18 2x18 1x36 2x36

Optics

Asymmetrical

with symmetric aluminium asymmetric reflector

reflector and with electromagnetic supply unit, IP66 - Class II

Power (W)

TUNNEL54 SERIES Tunnel projectors in AISI 316L stainless steel, glass diffuser with symmetric aluminium reflector and with electromagnetic supply unit, IP66 - Class II

10

1x18 2x18 1x36 2x36 1x54 2x54

Optics

Lampholder and lamp type

G13 T8 Asymmetrical G5 T5

Palazzoli Code

Pack Q.ty

153131 153132 153231 153232 153961 153962

1 1 1 1 1 1

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.

Technical data pages 14รท15 Dimensions page 15


LIGHTING SYSTEMS Enclosures for single-pole cables for tunnel projectors

Line cable sections

TUNNEL54 SERIES Enclosures for through line for single-pole cables for gallery projectors, spur with cable gland, IP66 - > IK10 400°C for 120’

2x (1x4mm2) 2x(1x6mm2) 2x (1x10mm2) 2x(1x16mm2) 2x (1x25mm2) 2x(1x35mm2) 2x (1x50mm2) 2x(1x70mm2)

Terminal board

Systems for tunnels

External size (mm)

Line cable glands

M16 (4,5-10mm) 185x185x105 M20 2x16mm2 (7-13mm) M25 2x40mm2 185x252x152 (9-17mm) M32 2x70mm2 252x315x193 (11-21mm) 2x6mm2

Palazzoli Code

Pack Q.ty

151011

1

151022

1

151034

1

151045

1

Palazzoli Code

Pack Q.ty

151111

1

151122

1

151134

1

151145

1

Palazzoli Code

Pack Q.ty

151311

1

151322

1

151334

1

151345

1

850°C for 90’

Line cable sections

TUNNEL54 SERIES Containers for line bottom for single-pole cables for tunnel projectors, spur with cable gland IP66 - > IK10 400°C for 120’

2x (1x4mm2) 2x(1x6mm2) 2x (1x10mm2) 2x(1x16mm2) 2x (1x25mm2) 2x(1x35mm2) 2x (1x50mm2) 2x(1x70mm2)

Terminal board

External size (mm)

Line cable glands

M16 (4,5-10mm) M20 2x16mm2 (7-13mm) M25 2x40mm2 185x252x152 (9-17mm) M32 2x70mm2 252x315x193 (11-21mm) 2x6mm2

185x185x105

fire proof page 8

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.

850°C for 90’

Line cable sections

TUNNEL54 SERIES Enclosures for through line for single-pole cables for gallery projectors, spur with cable gland, IP66 - > IK10 400°C for 120’ 850°C for 90’

2x (1x4mm2) 2x(1x6mm2) 2x (1x10mm2) 2x(1x16mm2) 2x (1x25mm2) 2x(1x35mm2) 2x (1x50mm2) 2x(1x70mm2)

Terminal board

External size (mm)

Line cable glands

M16 (4,5-10mm) 185x185x105 M20 2x16mm2 (7-13mm) M25 2x40mm2 185x252x152 (9-17mm) M32 2x70mm2 252x315x193 (11-21mm) 2x6mm2

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.

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 400°C x 120’ and 850°C x 90’applies to enclosure. Complementary items: fastening brackets on page 301. 2P+= 16A IP67 plug on page 13. Technical data pages 14÷15 Dimensions page 15

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Systems for tunnels

LIGHTING SYSTEMS Enclosures for multipole cables for tunnel projectors

Line cable sections

TUNNEL54 SERIES Enclosures for through line

Terminal board

gallery projectors, spur IP66 - > IK10

Palazzoli Code

Pack Q.ty

4x4mm2/

4x6mm2

151241

1

151242

1

M40 (19-28)

151252

1

M40 increased (22-32)

151264

1

M50 (32-38)

151275

M63 (37-44)

151285

1

Line cable glands

Palazzoli Code

Pack Q.ty

M32 (11-21)

3G (2F+=) 6mm2 4x10mm2/ 3G (2F+=) 10mm2

with cable gland

Line cable glands

3G (2F+=) 4mm2 4x6mm2/

for multipole cables for

External size (mm)

4x16mm / 2

4x16mm2 185x252x152

3G (2F+=) 16mm2 4x25mm / 2

400°C for 120’ 850°C for 90’

3G (2F+=) 25mm2

4x40mm2

4x35mm2/ 3G (2F+=) 35mm

2

3x50mm2 +25mm2/ 3G (2F+=) 50mm2 3x70mm2+35mm2

4x70mm2 252x315x193

3G (2F+=) 70mm

2

Line cable sections

TUNNEL54 SERIES Enclosures for through line

Terminal board

4x4mm2/ 3G (2F+=) 4mm

2

4x6mm2

4x6mm2/

for multi-pole cables for gallery projectors, spur

3G (2F+=) 6mm

IP66 - > IK10 400°C for 120’ 850°C for 90’

151441

1

151442

1

M40 (19-28)

151452

1

M40 increased (22-32)

151464

1

M50 (32-38)

151475

M63 (37-44)

151485

1

Line cable glands

Palazzoli Code

Pack Q.ty

M32 (11-21)

151641

1

151642

1

M40 (19-28)

151652

1

M40 increased (22-32)

151664

1

M50 (32-38)

151675

M63 (37-44)

151685

M32 (11-21)

2

4x10mm2/ 3G (2F+=) 10mm2

with cable gland

External size (mm)

1

4x16mm2/

4x16mm2 185x252x152

3G (2F+=) 16mm2 4x25mm2/ 3G (2F+=) 25mm2

4x40mm2

4x35mm / 2

3G (2F+=) 35mm2

fire proof page 8

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).

Characteristics: Spur with socket-outlet 16A - 2P+=. Resistance at 400°C x 120’ and 850°C x 90’applies to enclosure. Complementary items: fastening brackets on page 301. 2P+=16A IP67 plug on page 13.

3x50mm2 +25mm2/ 3G (2F+=) 50mm2 3x70mm +35mm 2

2

4x70mm2 252x315x193

3G (2F+=) 70mm2

Line cable sections

Terminal board

TUNNEL54 SERIES

4x4mm2/

Bar enclosures for

3G (2F+=) 4mm2

4x6mm2

4x6mm2/

power supply lines for tunnel projectors

3G (2F+=) 6mm

2

4x10mm2/ 3G (2F+=) 10mm2

IP66 - > IK10 400°C for 120’

External size (mm)

1

4x16mm2/

4x16mm2 252x185x152

3G (2F+=) 16mm2 4x25mm / 2

850°C for 90’

3G (2F+=) 25mm2

4x40mm2

4x35mm / 2

3G (2F+=) 35mm2 3x50mm2 +25mm2/ 3G (2F+=) 50mm2 3x70mm +35mm 2

2

3G (2F+=) 70mm2

12

4x70mm2 315x252x193

1 1

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. Technical data pages 14÷15 Dimensions page 15


Technical accessories for interlocked socket-outlets, for electric fans

Systems for tunnels

For windows type

Line cable glands

Palazzoli Code

Pack Q.ty

F5

M40 (19÷28) M40 increased (22÷32) M50 (32÷38) M63 (37÷44)

151930 151931 151932 151933

1 1 1 1

TUNNEL54 SERIES Raised closing flanges in aluminium alloy with brass cable gland

fire proof page 8

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.

IP67 - > IK10 400°C for 120’ 850°C for 90’

ALUPRES SERIES

Per finestre tipo

Overhang (mm)

Palazzoli Code

Pack Q.ty

F5

80

540065

1

Raised closing flanges in aluminium alloy IP67 - > IK10

Complementary items: nickel-plated brass cable glands on page 9.

400°C for 120’ 850°C for 90’

TUNNEL54 SERIES

Uses: they close unused windows. They enable large cables or conduits to be inserted into the enclosure.

Material

Palazzoli Code

Pack Q.ty

AISI 316L stainless steel

151900

1

For boxes with external dimensions (mm)

Palazzoli Code

Pack Q.ty

185x185 / 252x185 185x252 / 315x252 252x315

151901 151902 151903

1 1 1

Pair of supports for fixing socket-outlets to roof with

Characteristics: complete with adjustable roof fitting, 50x30mm section and socket-outlet fixing screws.

RCCB for electric fans

Material

TUNNEL54 SERIES Pair of supports

AISI 316L stainless steel

Equipment: fastening screws for enclosures.

for fixing tunnel enclosures

Technical data pages 14÷15 Dimensions page 15

13


Systems for tunnels Reference standards

Resistance to fire CEI EN50200 CEI EN 50362 CEI 20-36

General features

Resistance to excess heat ANAS 08-09-99 Prot. 7735

Housings

Terminals

CEI EN50298 CEI 17-71 CEI 23-48

CEI EN 60947-7-1 CEI 17-48

THEinstallations STANDARDSin : tunnels represent particular applications that, for the Due to the complexity of the problems involved, electric 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 400°C 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 850°C (+ 40°C tolerance) by means of thermocouples, on the boxes or on the connectors. Resistance up to 400°C 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.

230/400V Flame 830˚C

Flame 830˚C

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.

14


Systems for tunnels

Specifications

METAL

CASINGS:

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 crosssection of between 1.5 and 70 mm2. The characteristics of the terminals allow performances up to the levels shown in the table.

Characteristics of the connecting terminals of the cables in the boxes

Rated cross-section mm2 Rated thermal current Ith (A) Short duration rated current Icw (kA) Tearing resistance (N) Minimum cross-section that can be clamped (mm2) Maximum cross-section that can be clamped (stiff conductor) mm2 Maximum cross-section that can be clamped (flexible conductor) mm2 Rated voltage of insulation Ui (V)

(fixing)

e) ol nh to ut (b

(fixing)

10 57 1,2 90 4 10 6

16 76 1,92 100 6 16 10

25 101 3 135 10 25 16

35 125 4,2 190 16 35 25

50 192 6 230 16 50 35

F

*external earth screw

6 41 0,72 80 1 6 4 500

A (mm)

B (mm)

C (mm)

D (mm)

E (mm)

185 252 185 252 315

185 185 252 315 252

105 152 152 193 193

171 236 169 224 300

171 169 236 300 224

F *screw (mm)

6 7 7 9 9

M6 M6 M6 M10 M10

25

Enclosures for tunnels 18 W

Plugs and socket-outlets for tunnels

36/54 W

Tunnel projectors

15

70 232 8,4 285 16 70 50


55233/07

Applicable References A20 Messina - Palermo 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

export@palazzoli.com

www.palazzoli.com

S.S. 612 GALLERIA CEMBRA Trento AUXILIARY SERVICE SYSTEMS Distribution boards with interlocked sockets for niches, by-passes and lay-bys

Palazzoli S.p.A. Via F. Palazzoli, 31 - 25128 Brescia, Italia Tel. +39 030 2015.1 - Fax +39 030 2015.258

Tunnel guide line  

Certified Compliant to the European Parliament Directive 2004/54/EC relative to the minimum safety requirements for tunnels on the TERN - Tr...