tunnel guide line

2007/08 Edition

Systems for tunnelsCompliant to the European Parliament Directive 2004/54/EC

relative to the minimum safety requirements for tunnels on the TERN - Trans European Road Network.

850°C - 90’ 400°C - 120’

Certified

Introduction

ItalyIn 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)

AxisPatraiSofiaBucarestPortugalPortugalSpainNorth triangle

SectionVia EgnatiaPatheSofia-KulataLisbon - ValladolidLa Coruna - LisbonSiviglia - LisbonaHelsinki - Vaalimaa

Start of Works2006200820102010StartedStarted2015

EuropeIn use (excluding Italy): 171 tunnels (all part of theTrans 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. Whenbuilding quite short tunnels, in the order of a hundred meters, the work is almost exclusively building work and the possibletechnological fittings, such as for instance lighting, are optional and there are no particular requirements. It is quite a different matterwhen the tunnel is long, where the lighting, ventilation, luminous signs, air conditioners and fire-prevention systems are all essentialboth during normal use and in the case of an emergency. The complexity of the project and the entity of the consequent risks inemergency situations, increase according to the length of the tunnels and the amount of traffic, to the extent where long tunnels canbe 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 reliableand safe, but it appears that, also in this sector, there is the traditional underestimation of electrical installations; this can be seen bythe total lack of regulations or guidelines provided by CEI and CENELEC. Even the EC Directive 2004/54, that constitutes the mostimportant document on minimum European safety regulations for building tunnels, dedicates just a few lines to the requirements ofthe electrical fittings and unequivocally reveals a practically total lack of involvement of any experts in our sector. The mainconsequence of this deficiency is the lack of consistency in electrical regulations, mainly established from case to case, by the projectowners, or individual engineers in the tender document specifications. The lack of specific product regulations, harmonized at aEuropean level, prevents constructors from designing standard electrical components, checked using standardized and unequivocaltesting 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 andespecially in safety issues; recent tragic accidents prove how urgent it is to consider the machines, electrical and electronic devicesand fittings from a global point of view, in order to search for a synergy which will lead to a more reliable construction and installationtechnologies. 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 alsoexperts in electrical accident prevention standards. Following the results of this research, and in view of the present and futuredevelopment in the sector, it has designed a series of standard IMQ certified components, using innovative concepts, coherent withthe 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 forworkers and a contribution for the national and international regulatory authorities who deal with safety in road tunnels. As can benoted in chart 1, the work prospects in this fundamental sector, both at a national and European level, and also short term, areanything but negligible and deserve the attention of the professionals and businessmen working in this field and, at least, a specificCEI 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

AxisGreat BritainBenelux

GdanskViennaIrelandGreat Britain

SectionVarious

Gdansk - KatowiceKatowice - BrnoBrno - ViennaDublin - LarneHule - Liverpool

Start of Works2010

20102010200920102015

3

Italy only:

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

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

CEE (including Italy)

Juridical regulations:Directive2004/54/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 theenvironment, 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 particularrequisites typical of tunnels. A distinction is made between the provisions which have a juridical value, such as EC Directives, laws, decrees, ministerial circularletters, from those which are purely technical, such as standards, recommendations, guides, reports, technical specifications. Thelatter can only assume a coercive value if they are imposed by juridical dispositions or by tender contracts stipulated between aprincipal and a supplier. It should be mentioned that, as in most cases these works are subject to public tenders, which are generallyextended at a European level, the non-juridical rules have to at least be coherent with the standards, guidelines or reports issued byrecognized authorities. If there are no specific publications, the workmanship standards must be based on scientifically coherentstandards 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 tunnelson the TERN (Trans European Road Network) as defined in Decision 1692/96/EC. Despite referring only to the most importanttunnels in Europe, it constitutes a fundamental reference document. It is quite specific with regards to the geometry, conformation ofthe tunnels and the functional and safety technological services, such as ordinary lighting, emergency and safety lighting, luminousroad signs, ventilation and emergency signs, rescue and escape routes. It does not provide any particular details on the choice ofelectrical materials and the design and installation criteria which must be used for electrical systems. It does not even make anyreference 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 topworkmanship standards. It recognizes that the CEI and UNI Standards have the undisputable prerogative of being the source of suchworkmanship standards. This also confers legal validation to the Standards, though it does not make them mandatory. It is applicableto the generality of cases and therefore also to tunnels. Law 46/90 however is not applicable as it refers to interior electrical fittings, evenif 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 . Itimplements the UNI1 2899-1 Standard that covers technical lighting. This Decree was integrated by Directive October 24 2000 andM.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 preciserulings, outlines the ways to limit the amount of dangerous vehicles in the tunnel and restrictions on speed and overtaking. From atechnical point of view, it established the principle of the relationship between the different regulations, with the functional andgeometrical features of the tunnels and traffic flow. It establishes the obligation to check that the lighting system complies with therecommendations 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 columnsand fire-prevention extinguishers at the lay-bys, danger warning road signs spaced according to the sections of the tunnel, but inany case at a distance of no less than 500m. When tunnels are 2000m or over it is necessary to install fire hydrants compliant toUNI 45 every 200m. For tunnels which have surveillance systems or control centres, it is mandatory to prepare a safety manualcompliant to L.D. 626/94 (where the tunnel is considered a work place). The Decree set a deadline of June 30 2001 for tunnels tocomply 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 theindividual topics and their various difficulties. In the case in question, it is necessary to divide the topic into at least threeseparate issues: the electrical and electronic system with the relative components according to CEI Standards in Italy, toCENELEC 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 arecoherent with the IEC international publications; technical lighting intended as the design, installation and testing of lightingparameters in reference to both natural and artificial light is regulated in Italy by UNI Standards. The accredited standards ata European level are provided by CEN (European Committee for Standardization) where the Technical Committee 169 dealswith technical lighting and by CIE (Commission International de l'Eclarage) that exclusively studies technical lighting and hasa 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 anddimensional 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 ahundred 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 simplespecification imposition: "all the electrical and electronic systems and materials must comply to CEI Standards" is anythingbut univocal. For instance, the plates used for domestic HI-FI systems which are 0.3 mm2 and insulated with light PVC, andthe cables which are fireproofed with mineral insulation all comply to CEI Standards. For each Standard only the abbreviatedtitle 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 availablefree 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 arefitted 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 inthe 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 830°C; 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 combineit with generator groups);

CEI 22-17: Activators for alternate current motors at various speeds ( activation and inversion of the ventilators installed inthe tunnel or in ventilation stations);

CEI 23-12: Plugs and sockets for industrial use ( connections which can be sectioned from the lighting systems or othercomponents installed in the tunnel);

CEI 32-1: Fuses (selective protection for devices and ventilators installed in the tunnel and which derive from backbonecables);

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 inthe tunnel and elsewhere);

CEI 64-8/5: Low voltage electrical systems. Choice and installation of the electrical systems (applicable to the generalspecifications 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 tolighting systems installed outdoors, including tunnels, and section 715 relative to systems installed in placeswith high risk levels in the presence of fire, which outline the main principles to prevent the electrical wiringfrom 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 forelectrical components installed in tunnels);

CEI 70-3: Protection index of the covering against collision (assessment of the IK level suitable for electrical componentsinstalled in tunnels);

We can conclude this list of CEI Standards by commenting that, at present, there are no specific standards which regulate thesystems or materials destined for use in tunnels. In particular, the fire-proof levels are assessed, which intend to guaranteethat the electrical system continues to function even in the presence of fire, exclusively with regards to the cables. No typesof 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 referencedocument in this report; it should be remembered that the UNI Standards, pursuant to Law 186/68, provide the prerogative ofworkmanship standards and it seems justified to acknowledge this priority when faced with other incoherent standards orrecommendations. CIE Publication 88: This refers to the photometrical features in tunnels and comprises the fundamentalreference document of the M.D. of December 6 1999 mentioned above. Standards currently being updated: CENCR14380, 2003 Edition: This refers to the technical lighting standards in tunnels and is very similar to the UNI11085Standard. 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 detailedregulations regarding all aspects of technological systems installed in tunnels and is the fundamental documents for the ANASTechnical Specifications. This circular letter was taken into account during the preparation of this report, though notexclusively, 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 Seriespage 9

Electric fan line bar


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

400°C - 120’INTEK certified

7

Projectors for lanes andrecesses


Spurs for single-pole cable


Spurs for multi-pole cable


Projector line bar


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.

LIGHTING SYSTEMS

The TUNNEL54 system is ‘FIREPROOF’. The use ofmetal, ceramics and heat-hardening resins ensuresmaximum resistance to fire and corrosion. The

FIREPROOF approval guarantees thatthe 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 90minutes (EN 50200).

Palazzoli in the road systems: The quality and performance of the Palazzoli products meet the specifications for viaducts,transformation cabinets, serviceareas, turn-offs, etc even in areaswith ATEX explosion hazard.

TUNNEL54 SERIES – SYSTEMS FOR TUNNELSThis is a range designed for the creation of electrical systems for ventilation and illumination insidethe galleries and road systems in compliance with the new European Directive 2004/54/CE andcurrent 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 alluminiumalloy or AISI 316L stainless steel. They are built to ensure continuous service even in fires and arecertified 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 FIREWITHOUTCOMPROMISES The TUNNEL54 interlocked socket-outlets forelectric fans in the dual versions 63A and125A ensure operation at 400°C for 120’.This performance is obtained only with ratedcurrent circuit breakers at ambienttemperature, respectively at 400A and 200Awith closure power from 1250A.

GUARANTEED CABLEPERFORMANCE The unsurpassed resistance to heat of thebrass terminal blocks on a ceramic base andthe terminals with dual anti-loosening screwsare the only solution to ensure electricalcontinuity up to 850°C for 90’.

COMFORT ANDSAFETY The TUNNEL54 series projectors are the idealsolution for lighting the galleries withfluorescent T5 and T8 lamps up to 54W.They are made of a single drawn piecewithout welding seams and are therefore notsubject to corrosion.

8

Systems for tunnels

Techniques and advantages

850°C - 90’IMQ certified

400°C - 120’INTEK certified

Technical datapages 14÷15Dimensionspage 15

Systems for tunnels

9

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

Equipment:provided with washers and screws for fixing accessories. Internal andexternal earth terminal.

Characteristics:upper side passage with F5window.

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

400°C for 120’

Rated Frequency Rated Poles Palazzoli Pack

current (Hz) voltage Code Q.ty

(A) (V)

6350-60 690 3P+=

151880 1125 151881 1

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

TUNNEL54 SERIES

Plugs for gallery

electric fans,

IP66 - > IK10

400°C for 120’

Characteristics:3-pole terminal block withbrass conductor bars andterminals to prevent loosening with doublescrews in brass fixed to aceramic base. 2 IP68 cableglands in nickel-plated brasswith ISO thread with metricpitch with radial tightening ofthe cable. M6 type externaland 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

400°C for 120’

850°C for 90’

Line Terminal External Line cable Palazzoli Pack

cable Block dimensions glands Code Q.ty

sections

3x10mm2

M403x16mm2 3x25mm2 185x185x105

(19-28mm)151553 1

3x25mm2

M403x35mm2 3x40mm2 increased 151564 1

(22-32mm)

3x50mm2252x185x152 M50

151575 1(32-38mm)

3x70mmqM63

151585 13x70mm2

(37-44mm)

Rated Frequency Rated Poles Palazzoli Pack

current (Hz) voltage Code Q.ty

(A) (V)

6350-60 690 3P+=

151890 1125 151891 1

fire proofpage 8

fire proofpage 8


10

Systems for tunnels

LIGHTING SYSTEMSProjectors with symmetric and asymmetric tunnel reflector

Equipment:M25 brass cable gland.Stainless steel brackets for wallor roof installation.

Characteristics:AISI 316L stainless steel body,tempered glass diffuser 6mmthick.Diffuser fall-preventionsystem. Terminal block withsectionable multipole safetyfuse, male-female.Ultra-polished aluminium reflector.

Uses:Suitable for lighting lanes andrecesses, 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

1x182x181x362x36

1111

152101152102152201152202

G13 T8Symmetrical



1x182x181x362x361x542x54

111111

152131152132152231152232152961152962

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 forwall or roof installation.

Characteristics:AISI 316L stainless steelbody, tempered glass diffuser6mm thick.Diffuser fall-preventionsystem. Terminal block withsectionable multipole safetyfuse, male-female.Ultra-polished aluminiumreflector.

Uses:Suitable for lighting lanes and recesses, railways andtunnels.

TUNNEL54 SERIES




reflector and with


IP66 - Class II



1x182x181x362x36

1111

153101153102153201153202

G13 T8Asymmetrical



1x182x181x362x361x542x54

111111

153131153132153231153232153961153962

G13 T8

G5 T5

Asymmetrical

TUNNEL54 SERIES




reflector and with


IP66 - Class II

cable glandM25 brass

symmetrical reflector

stainlesssteel

glass

1 entry

asymmetric reflector

protectionwith fuse


Systems for tunnels

11

LIGHTING SYSTEMSEnclosures for single-pole cables for tunnel projectors

Characteristics:2-pole terminal block withbrass conductor bars andterminals to prevent loosening with doublescrews in brass fixed to aceramic base.IP68 cable gland in nickel-plated brass with ISOthread with metric pitch withradial tightening of thecable. M6 type external andinternal earth terminal.Protection of the supplyphase of the lighting bodythrough the E14-D01 ceramic fuseholder basecomplete with fuses.The fuse based is precabled at the spur.Spur with M25 cable gland(9-17mm clamp).

Complementary items:fastening brackets on page13.

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’

Line cable Terminal External Line cable Palazzoli Pack

sections board size (mm) glands Code Q.ty

2x (1x4mm2)2x(1x6mm2)

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

M16(4,5-10mm)

M20(7-13mm)

M25(9-17mm)

M32(11-21mm)

2x6mm2

2x16mm2

2x40mm2

2x70mm2

1

1

1

1

151011

151022

151034

151045

185x185x105

185x252x152

252x315x193

TUNNEL54 SERIES

Containers for line bottom


tunnel projectors, spur with

cable gland IP66 - > IK10

400°C for 120’

850°C for 90’



2x (1x4mm2)2x(1x6mm2)


M16(4,5-10mm)

M20(7-13mm)

M25(9-17mm)

M32(11-21mm)

2x6mm2

2x16mm2

2x40mm2

2x70mm2

1

1

1

1

151111

151122

151134

151145

185x185x105

185x252x152

252x315x193

M6 type external and internalearth terminal. Protection ofthe supply phase of the lighting body through theE14-D01 ceramic fuseholderbase complete with fuses.The fuse based is precabledat the spur. Spur with socket-outlet 16A - 1P+N=.Resistance at 400°C x 120’and 850°C x 90’applies toenclosure.

Complementary items:fastening brackets on page301. 2P+= 16A IP67 plug onpage 13.

Characteristics:2-pole terminal block withbrass conductor bars and terminals to prevent loosening with double screwsin brass fixed to a ceramicbase. IP68 cable glands innickel-plated brass with ISOthread with metric pitch withradial tightening of the cable.

TUNNEL54 SERIES



gallery projectors, spur with

cable gland, IP66 - > IK10

400°C for 120’

850°C for 90’



2x (1x4mm2)2x(1x6mm2)


M16(4,5-10mm)

M20(7-13mm)

M25(9-17mm)

M32(11-21mm)

2x6mm2

2x16mm2

2x40mm2

2x70mm2

1

1

1

1

151311

151322

151334

151345

185x185x105

185x252x152

252x315x193

fire proofpage 8


12

Systems for tunnels

LIGHTING SYSTEMSEnclosures for multipole cables for tunnel projectors

Characteristics:4-pole terminal block withbrass conductor bars andterminals to prevent loosening with doublescrews in brass fixed to aceramic base. IP68 cablegland in nickel-plated brasswith ISO thread with metricpitch with radial tighteningof the cable. M6 type external and internal earthterminal. Protection of thesupply phase of the lightingbody through the E14-D01ceramic fuseholder basecomplete with fuses. Thefuse based is precabled atthe spur. Spur with M25cable gland (9-17mmclamp).

TUNNEL54 SERIES


for multipole cables for

gallery projectors, spur

with cable gland

IP66 - > IK10

400°C for 120’

850°C for 90’



4x4mm2/

3G (2F+=) 4mm2

4x6mm2/

3G (2F+=) 6mm2

4x10mm2/

3G (2F+=) 10mm2

4x16mm2/

3G (2F+=) 16mm2

4x25mm2/

3G (2F+=) 25mm2

4x35mm2/

3G (2F+=) 35mm2

3x50mm2 +25mm2/

3G (2F+=) 50mm2

3x70mm2+35mm2

3G (2F+=) 70mm2

M32(11-21)

M40(19-28)

M40increased

(22-32)

M50(32-38)

M63 (37-44)

4x6mm2

4x16mm2

4x40mm2

4x70mm2

151241

151242

151252

151264

151275

151285

1

1

1

1

1

1

185x252x152

252x315x193

Characteristics:Spur with socket-outlet 16A - 2P+=.Resistance at 400°C x 120’and 850°C x 90’applies toenclosure.

Complementary items:fastening brackets on page 301.2P+=16A IP67 plug on page 13.

TUNNEL54 SERIES


for multi-pole cables for

gallery projectors, spur

with cable gland

IP66 - > IK10

400°C for 120’

850°C for 90’



4x4mm2/

3G (2F+=) 4mm2

4x6mm2/

3G (2F+=) 6mm2

4x10mm2/

3G (2F+=) 10mm2

4x16mm2/

3G (2F+=) 16mm2

4x25mm2/

3G (2F+=) 25mm2

4x35mm2/

3G (2F+=) 35mm2

3x50mm2 +25mm2/

3G (2F+=) 50mm2

3x70mm2+35mm2

3G (2F+=) 70mm2

M32(11-21)

M40(19-28)

M40increased

(22-32)

M50(32-38)

4x6mm2

4x16mm2

4x40mm2

4x70mm2

151441

151442

151452

151464

151475

151485

1

1

1

1

1

1

185x252x152

252x315x193

Characteristics:4-pole terminal block withbrass conductor bars andterminals to prevent loosening with doublescrews in brass fixed to aceramic base. 2 IP68 cableglands in nickel-plated brasswith ISO thread with metricpitch with radial tightening ofthe cable. M6 type externaland internal earth terminal.

On request:stainless steel enclosure.

TUNNEL54 SERIES

Bar enclosures for

power supply lines for

tunnel projectors

IP66 - > IK10

400°C for 120’

850°C for 90’



4x4mm2/

3G (2F+=) 4mm2

4x6mm2/

3G (2F+=) 6mm2

4x10mm2/

3G (2F+=) 10mm2

4x16mm2/

3G (2F+=) 16mm2

4x25mm2/

3G (2F+=) 25mm2

4x35mm2/

3G (2F+=) 35mm2

3x50mm2 +25mm2/

3G (2F+=) 50mm2

3x70mm2+35mm2

3G (2F+=) 70mm2

M32(11-21)

M40(19-28)

M40increased

(22-32)

M50(32-38)

4x6mm2

4x16mm2

4x40mm2

4x70mm2

151641

151642

151652

151664

151675

151685

1

1

1

1

1

1

252x185x152

315x252x193

fire proofpage 8

M63 (37-44)

M63 (37-44)


Systems for tunnels

13

Technical accessories for interlocked socket-outlets, for electric fans

Characteristics:cable gland in nickel-platedbrass with ISO thread withmetric pitch with radial tightening of the cable.

Complementary items:socket-outlets for electricfans on page 9.

TUNNEL54 SERIES

Raised closing flanges in

aluminium alloy with

brass cable gland

IP67 - > IK10

400°C for 120’

850°C for 90’

Uses:they close unused windows.They enable large cables orconduits to be inserted intothe enclosure.

Complementary items:nickel-plated brass cableglands on page 9.

ALUPRES SERIES

Raised closing flanges in

aluminium alloy

IP67 - > IK10

400°C for 120’

850°C 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 (19÷28) 151930 1

F5M40 increased (22÷32) 151931 1

M50 (32÷38) 151932 1M63 (37÷44) 151933 1

Characteristics:complete with adjustableroof fitting, 50x30mm section and socket-outletfixing 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 1AISI 316L stainless steel 185x252 / 315x252 151902 1

252x315 151903 1

fire proofpage 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 17-48CEI 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 theElectrical installations in tunnels constitute, an view of the complex problems that they imply, particular applications thatpresently 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 MinisterialDecree 5-6-2001) which recently emerged in a EU context in the 2004/54/EC Directive which lays down the minimum safetyrequisites in road tunnels. However, as far as electric circuits are concerned, only guidelines can be referved to from thecurrent 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 of400°C for at least 90 minutes is required.

The Palazzoli proposal against the risks of fireThe main problem, solved with Palazzoli products for tunnels, is that of preventing the fire, affecting the connections, fromcausing 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 fromfireproof 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 asshown by the test carried out at the IMQ laboratory, applying the procedure laid down by the IEC EN 50200 standard, directingthe 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 apositive 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 nointerruptions or short circuits between the phases and to the earth. Flame at 830° calibrated with thermocouples, incompliance with the IEC EN 50200 test procedure.

THE STANDARDS:

Flame830˚C

Flame830˚C

230/400V

15

Systems for tunnels

SpecificationsThe metal casings of the boxes and connectors with flat plugs are made from very thick pressure die-cast UNI 5076 light alloy with a highaluminium 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 electricparts; 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 junctionsThe junctions in the boxes are made by screw terminals with a brass body mounted on bars insulated by ceramic supports; this way a rigid systemis 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 bymeans of metal inserts, at a good distance from the live parts, avoids the contact towards earth under the action of the flames. The screw clampingson the brass body guarantee against loosening due to corrosion in a damp environment and to fast thermal variations which occur during a fire.

The unionsThe 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 featuresThe 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 mm2. 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 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)

6 10 16 25 35 50 7041 57 76 101 125 192 2320,72 1,2 1,92 3 4,2 6 8,480 90 100 135 190 230 2851 4 6 10 16 16 166 10 16 25 35 50 704 6 10 16 25 35 50500

18 W 36/54 W

25

(fixing)

(fix

ing)

*external earth screwF (buttonhole)

185 185 105 171 171 6 M6252 185 152 236 169 7 M6185 252 152 169 236 7 M6252 315 193 224 300 9 M10315 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

[email protected]

5523

3/07

A20 Messina - Palermo

Applicable References

GALLERIA PIANAS. Stefano di Camastra

LIGHTING SYSTEMUnipolar, multipolar derivations andline breakers for flood light lines

Nuova Aurelia GALLERIA MARINASCOLa Spezia

VENTILATION SYSTEMInterlocked Sockets, plugs and linebreaker enclosures to power theelectrical ventilation system

S.S. 612 GALLERIA CEMBRATrento

AUXILIARY SERVICE SYSTEMSDistribution boards with interlockedsockets for niches, by-passes and lay-bys

tunnel guide line

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