Please note that the words enclosed in gray are actually help buttons that provide much of the same information as contained in this document. Specifications and Installation Drawings can be downloaded via links located on the form. A lot of the selections can be easily changed at your site, but some of the information is required for TML to configure and calibrate the monitor. The required information includes the Customer Contact Information, the Flange to Flange Calibration Distance, Correction for Stack Exit Opacity Pathlength, Specify Full Output Units and full Scale, and the Maximum Opacity Limit. The form cannot be submitted electronically unless the required information is entered. Once the ‘Submit’ button is clicked on, a list of the information entered in the form is submitted to TML via email. A copy of the form can be printed for your records.

1. CUSTOMER CONTACT INFORMATION:

Fill out your name, phone number, email address and other information. The Stack Identification should be the name of the stack or duct that the monitor will be on. Some sites may have a name such as “Boiler1” others may have names such as “West Stack” or a more descriptive name of the process.

2. MOUNTING FLANGES (Not typically provided)

The Standard mounting flanges are 2" 150lb ANSI flanges and are to be supplied by the customer. The flanges are welded to 2" Sch. 40 pipe that is also customer supplied. If the application calls for mounting pipes longer than 13", larger diameter pipes should be considered in order to maintain good alignment (consult drawing 1800-0013).  If you are adapting to an EXISTING flange or using mounting pipes other than 2" Sch. 40 , select Other and consult the TML factory to specify the configuration.

3. FLANGE TO FLANGE CALIBRATION DISTANCE

Record this distance in English or Metric units. This distance is to be measured from the outside of one mounting flange to the outside of the other mounting flange with an accuracy of +\-1% of the distance. (consult drawing 1800-0007) TML recommends that the user measure this dimension after the mounting pipe and flanges have been installed and consider using a laser tape device to make the measurement.
*NOTE: The accuracy of the factory calibration and opacity measurement are both dependent on this dimension being measured and reported accurately.

4. PROCESS TEMPERATURE

• Report the maximum and minimum process temperature Range including upset conditions.

• Report the Typical process temperature under normal operating conditions.

This information is necessary to ensure that the hardware configuration chosen is adequate for the user's application (high temperature seals, stainless steel nozzles and a heat shield may be required when the temperature exceeds 500 ºF)

5. PROCESS STATIC PRESSURE
Record the process static pressure range in INCHES of WATER COLUMN at the monitor installation location.

This information is necessary to ensure that the hardware configuration chosen is adequate for the user's application (high positive pressure >5" H2O may require options)  

6. MOUNTING CLEARANCES

Review the proposed installation locations and reference the TML drawings. Check OK if sufficient clearances are available. Mark Other and consult the factory if alternative installation configurations are required. 

• Stack Equipment: Be certain that there is sufficient clearance between the stack mounted equipment and any potential obstructions (i.e.: distance to floor, horizontal distance to catwalk rail). Weather hood is…20" W x 22 ¼" L x 33" H. (See drawing 1800-0007).

7. PURGE FAIL CABLE LENGTH

The purge fail cable is supplied with the system and connects the Retroreflector with the Optical Head assembly. This cable must be routed through customer-supplied 1/2" (min.) flexible and rigid conduit. A Standard 40 feet (12.2meters) of purge fail cable will be provided with each monitor purchased. List cable lengths that exceed 40 feet under Other.

Consult the TML factory for pricing of cables greater than 40 feet in length.

8. DATA CABLE LENGTH

DATA CABLE LENGTH Direct Interface (Not provided with standard system, available as option)

The cost of the cables from the Optical Head to the output or display device has not been included in the COMS base price. TML will provide the cable at additional cost to the customer.

The user must determine the length of the data cable measured from the Optical Head to their DAS/PLC or other output device. Minimum recommended conduit size is 1/2". A Direct Interface configuration requires two cables; a non-shielded 4-conductor/20 AWG (Alpha 66-44) and a 6-shielded pair/24 awg (Alpha 6386/Belden 9991). Consult the TML factory for current price and delivery of data cable.

DATA CABLE LENGTH with Enhanced Remote (Not provided with standard system, available as option) The cost of the cable from the Optical Head to the output or display device has not been included in the COMS base price. TML can provide the cable at additional cost to the customer.

The user must determine the length of the data cable measured from the Optical Head to the Enhanced Remote Panel. Minimum recommended conduit size is 1/2". The Enhanced Remote Panel configuration requires only a single twisted pair, 16 AWG with shield (Alpha 5610B1601).  Consult the TML factory for current price and delivery of data cable.

9. OPTICAL HEAD POWER CIRCUIT CAPACITY

Enter the supply voltage and current capacity of the customer supplied circuits for the STACK equipment. Circuits must meet the following minimum requirements.

Stack Equipment: Maximum power draw is:

• 14VA single phase for the Optical Head

• 414VA single phase for one Purge Blower

• 828VA single phase for dual Purge Blowers

A minimum of one 115VAC single phase, 10A circuit is required. The customer is to hardwire 115VAC into the purge motor junction box of both the Retroreflector and Optical Head sides if a dual purge system is utilized.

10. CORRECTION FOR STACK EXIT PATHLENGTH

Most regulatory agencies require that monitor opacity readings be corrected to reflect the observable opacity where the emissions exit to the atmosphere. The EPA calls this the Path Length Correction Factor or PLCF.

Record the following to calculate the PathLength Correction Factor (PLCF):

• a.) Monitor Pathlength

Record the inside dimension of duct or stack at the monitor location.

• b.) Emission Pathlength

• For a round stack - record the inside diameter of duct or stack at the exit

• For square or rectangular duct or stack, record both dimensions at the exit.

11. MAXIMUM OPACITY LIMIT

Changes to US EPA regulations require manufacturers to configure and test COMs differently based on the user's maximum opacity emissions. Record the opacity limits imposed by your controlling regulatory agency.

If the user's operating permit includes both Instantaneous and Integrated opacity limits, please record both limits and the Integration period on the checklist.

12. SPECIFY FULL SCALE

The Standard output scaling includes:

Opacity = 100%
Optical Density = 2.000
Particulate Mass = Consult the TML factory

The user's operating permit may require a specific opacity full scale based on the classification of the emission source.

Calibration Configuration

The LightHawk 560 will output various information to confirm proper operation and validate the emissions data. The timing and sequence of the Calibration Cycle output may be controlled by:

• Auto Cal Sequence - The real time clock in the Optical Head determines the start and duration of each phase of the calibration data.

• External Mode Control - The user's DAHS, PLC or Data Logger circuits control the start time of a predetermined sequence or manually control individual output modes.

These methods may both be used. An example would be to use the Auto Cal feature to record the daily calibration data while the user's DAHS would poll the ZERO or UPSCALE data every 8 hours.

13. USE AUTO CAL SEQUENCE

Check YES if the Auto Cal sequence is to be used to collect calibration data. Check NO if the user will be exclusively using External Mode control.

14. USE EXTERNAL MODE CONTROL

Check YES if the External Mode control sequence is to be used to collect calibration data. Check NO if the user will be exclusively using Auto Cal.

15. SPECIFY CAL CYCLE OUTPUT TIMES:

Calibration information is usually provided on Channel 2. The standard auto cal reporting cycle is 120-seconds for each of the following phases: ZERO, UPSCALE (240-Sec total). PLCF and DUST values are not output in the standard configuration. Check YES to accept the Standard 120-seconds for ZERO and Upscale. If NO is selected, please specify on the checklist each phase duration you want. Each is independently programmable. Maximum allowable time is 2,880 seconds (max. 720 secs. each).

16. SYSTEM CONFIGURATION:

(Select one) Direct Interface or Enhanced Remote
The LightHawk560 is available in two basic configurations. The Direct Interface configuration does not have the Enhanced Remote Panel. The Direct Interface requires more wires to be run from the stack or duct. The Enhanced Remote option gives the user more information down at the ‘remote’ location and offers more inputs and outputs than the Direct Interface. The Enhanced Remote option requires only one cable with two wires to be run from the stack or duct to the Enhanced Remote Panel’s location.

This is option A, Direct Interface

17A. SPECIFY OUTPUT UNITS:

Check the analog output units your monitor is to report in, Opacity, Optical Density or Particulate Mass (select one) Standard default = Opacity

18A. CURRENT OUTPUTS:

The Direct Interface has two analog outputs available. They are isolated from each other and circuit common.

Channel 1 is always dedicated to the Instantaneous value and does not carry calibration values.  Channel 2 is always Selectable Average with calibration. If an output carries calibration values (Channel 2), the analog output will track the calibration values when it is commanded to go into calibration or when it is scheduled to go into calibration. If the output does not carry calibration values (Channel 1), the analog output will hold the last NORMAL mode value when the monitor is in a calibration mode.

Please select the output current configuration you want, 4 - 20 ma or 0 - 20 ma. Select only one.  Standard default = 4 - 20ma.

19A. RELAY OUTPUTS:

The Six Point I/O board uses 2 relays that can be configured to actuate on various output modes or monitor conditions. Select any two from the table below. These functions are set via jumper settings and can be easily modified at the site. Contacts are SPDT Form C. The two relays available can be configured as either Normally Open or Normally Closed via a jumper setting.  The standard selections most commonly chosen are “Calibration Data on Analog Outputs” and “Instrument Malfunction”. The following table lists the available selections.

20A. DIGITAL INPUT SELECTION

Digital Inputs
Two discrete inputs are provided to allow monitor output mode control by user supplied circuits.  These optical isolators are activated by either dry contact closures or +5VDC signal from a user-supplied circuit. These signals are transmitted to the Optical Head vi a the Data cable.  This configuration is field selectable and may be modified at the time of instrument start up The following definitions apply to the selection of the External Mode control digital inputs:

Force Upscale = The instrument goes into calibration UPSCALE mode. The calibration mechanism moves to the UPSCALE position. Analog output #1 holds the last stack value read, analog output #2 follows the UPSCALE value

Force Zero = The instrument goes into calibration ZERO mode. The calibration mechanism moves to the ZERO position. Analog output #1 holds the last stack value read analog output #2 follows the ZERO value.

Dump PLCF = The calibration mechanism moves to NORMAL position. Real time stack data appears on the LED readout and on analog output #1. Analog output #2 follows the PLCF value.

Dump Dust = The calibration mechanism moves to NORMAL position. Real time stack data appears on the LED readout and on analog output #1. Analog output #2 follows the DUST COMPENSATION value.

Force Cal Cycle = The calibration mechanism moves to ZERO, UPSCALE, PLCF, DUST COMPENSATION and then back to NORMAL. It remains in each mode for a configurable period of time.

This is Option B, Enhanced Remote Option

The Enhanced Remote has 8 isolated inputs available. The location and designation of each are fixed. To use any of these inputs, merely connect wires to the appropriate input. A simple jumper setting on the Multi- I/O board determines if they are activated by a dry contact or +5 VDC input.  Dry contact closure is the standard configuration. More information is provided on the Installation Drawings and in the Manual.

Input #1            Force Upscale
Input #2            Force Zero
Input #3            Dump PLCF
Input #4            Dump Dust Comp
Input #5            Force Cal Cycle
Input #6            Not Used
Input #7            Test Zero Scale
Input #8            Test Full Scale

17B. SPECIFY DESIRED ANALOG OUTPUTS:

The Standard Configuration includes:

Channel 1          Instantaneous Opacity, with cal values displayed.
Channel 2          Instantaneous Opacity, without cal values displayed.
Channel 3          PLCF
Channel 4          Dust Compensation

The Analog Outputs can be easily changed at a later date, through a list on the Enhanced Remote Panel. Choose the desired Analog Outputs from the following table:

Parameters for Analog Output 

There are eight relays (K1-K8) available on the LightHawk Multi I/O Module to interface with user circuits. Each relay is SPST with one normally open contact rated 3A max. The Standard Configuration includes:

K1        Analog outputs displaying calibration ZERO
K2        Analog outputs displaying UPSCALE calibration
K3        PLCF value being displayed on the analog outputs
K4        Analog outputs displaying any type of calibration data
K5        Data Valid (Failsafe)
K6        Instantaneous Opacity exceeds Level 1 set-point
K7        Average Opacity exceeds Level 1 set-point
K8        Purge Fail

The relays can also be easily changed at a later date, through a list on the Enhanced Remote Panel. Select options for the relay configurations from the following table:

Parameters for Relay Assignment
(Digital Output closure conditions)

19B. ENHANCED REMOTE PANEL POWER CIRCUIT CAPACITY

Maximum power draw is:
25 VA single phase for the remote equipment.

The Enhanced Remote Panel normally operates on a 115VAC, 60 HZ, single phase supply. The assembly is usually shipped with a standard straight 115VAC, 3-pronged molded power cord, 15'

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