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Teledyne Monitor Labs is a leading supplier of environmental monitoring
instrumentation, systems and software

 
LightHawk 560 Installation Checklist

Revision L -  April 12, 2006
 
Teledyne Monitor Labs | 5310 North Pioneer Road, Gibsonia, PA | Phone: 724-444-5000 | Fax: 724-444-5050
Monday-Friday, 8:00 a.m.- 4:45 pm
 
» How To Use This Document
» LightHawk Technical Drawings (for reference only)
» Download this Document
 

Note: When upgrading an opacity monitor the existing purge blowers are used. Due to the disturbance of dust, rust, and other particulate in the purge system during the installation process, and possible general deterioration of the blower, some users begin to experience excessive window dirt buildup requiring abnormal amounts of maintenance. This condition is beyond the responsibility of TML and can sometimes only be rectified by replacement of the deteriorating blower and/or purge hose.

1.    Customer Contact Information

 

Name:
Title:
Company:
Phone:
FAX:
Email:
Stack Identification:

 

 

 

 

 

 

2.   Mounting Flange           

 

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.

Please specify if the Standard Mounting Flange is sufficient or if larger diameter pipes will be used.

 

            

3.    Flange to Flange 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.

 

*NOTE: The accuracy of the factory calibration and opacity measurement are both dependent

on this dimension being measured and reported accurately.

 

  Feet       Inches

                                        

 

                                                            or

  Meters

 

 

 

4.    Process Temperature   

Range:   oF     Max:   oF

 

                                                         or

Range:   oC     Max:   oC

 

 

 

 

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)

 

Range: Inches of H2O

 

 

 

 

6.    MOUNTING CLEARANCE   

 

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.

 

       

 

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.

 

 Other: 

 

 

 

 

8.    DATA CABLE LENGTH   

 

The Data Cable is supplied at an additional cost.

 

FT (Additional cost option)

 

 

 

 

9.    POWER CIRCUIT CAPACITY   

 

Enter the supply voltage and current capacity of the customer supplied circuits for the STACK equipment.

 

STACK:     Volts       Amps

 

 

 

 

10.    CORRECTION FOR EXIT PATHLENGTH   

 

Most regulatory agencies require that monitor opacity readings be corrected to reflect the observable

opacity where the emissions exit to the atmosphere.

 

Monitor Pathlength:   ft       in

 

 

 

If Stack is Round:

 

Exit Pathlength:        ft       in

 

 

 

If Stack is Square:

 

Exit Pathlength Width:     ft       in
Exit Pathlength Length:    ft       in

 

 

 

 

 

 

11.    MAXIMUM OPACITY LIMIT   

 

Pending changes to US EPA regulations will 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.

 

Instantaneous Opacity Limit:   %
Averaging Period:   minutes
Average Opacity Limit:   %

 

 

 

 

 

 

 

12.    SPECIFY FULL SCALE   

The Standard output scaling includes:
Opacity = 100%
Optical Density = 2.000
Particulate Mass = Consult the TML factory

Choose YES to accept the Standard configuration described above. If you choose NO,

enter the desired full scale in the appropriate space provided in the checklist.

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

Accept Standard Configuration?        YES      NO (if NO, enter the desired full scale below)

 

Opacity         Optical Density        Particulate Mass (consult factory)

 

 

 

 

13.    AUTO CAL SEQUENCE   

 

           YES          NO

 

 

14.     EXTERNAL MODE   

 

            YES         NO

 

15.    CAL CYCLE OUTPUT   

 

Accept Standard 120 seconds for each cal phase?    YES      NO

(if NO, enter all times below)

 

ZERO
UPSCALE
PLCF
DUST COMP

 

 

 

 

 

 

 

 

16.    SYSTEM CONFIGURATION (SELECT ONE OF THE FOLLOWING)

 

 Direct Interface          Enhanced Remote

 

This is Option A, Direct Interface

17A.    SPECIFY OUTPUT UNIT   

 

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.    SPECIFY 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 pull-down menu. 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.

 

Relay 1
Relay 2

 

 

 

 

 

20A.    DIGITAL INPUT SELECTION   

 

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 via the Data cable.

 

Accept Standard Selection?    YES      NO  (if NO select desired configuration below)

 

Digital Input 1
Digital Input 2

 

 

 

 

If you have chosen a "Direct Interface" configuration, you are finished.

Click to submit.

 

 

This is Option B, Enhanced Remote Panel

 

17B.    ANALOG OUTPUT   

 

Choose YES to accept the Standard configuration described above. If you choose NO,

the user may choose other analog output configurations desired from the following list.

Choose the desired code from the pull-down menu.

 

Accept Standard Output Configuration?        YES          NO

 

Analog Output 1
Analog Output 2
Analog Output 3
Analog Output 4

 

 

 

 

 

18B.    Specify Relay Assignments   

 

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.

 

Accept Standard Relay Configuration?        YES          NO

 

K1
K2
K3
K4
K5
K6
K7
K8

 

 

 

 

 

 

 

 

 

19B.    DIGITAL INPUTS   

 

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.

 

20B.    POWER CIRCUIT CAPACITY      

 

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' long. Other cords

such as a 230VAC, 3-pronged cord can also be provided. The Enhanced Remote Panel power specifications

are: 85 to 265 VAC, 47 to 63 Hz, Single Phase, 25 VA maximum.

 

Power Circuit Capacity  Volts
Power Circuit Capacity  Amps

 

 

If you have chosen a "Enhanced Remote" configuration, you are finished.

Click to submit.

How to complete the LaserHawk360 Installation Checklist

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.

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.

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

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.

  • 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.

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.