Ludlum Measurements 4525-7000 User manual

Ludlum Model
4525-7000
4525-10500
4525-14000
Generation 5 Installation Manual
October 2023

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Statement of Warranty
Ludlum Measurements, Inc. warrants the portal monitor covered in this manual to be free of defects due to
workmanship, material, and design for a period of 24 months from the date of delivery. The calibration of a
product is warranted to be within its specified accuracy limits at the time of shipment. Accessories such as
computers, Universal Power Supplies (UPSs), cameras, network equipment, etc., are warranted by the
individual manufacturer, and are not covered by Ludlum Measurements.
This warranty excludes the replacement of instruments, detectors, or parts that are broken due to excessive
physical abuse, acts of nature such as lightening, or used for purposes other than intended. Warranty claims
requiring an onsite technician will cover labor and parts only. All related travel expenses such as airline fees,
meals and incidentals, and lodging are to be paid for by the customer and are not covered by the warranty.
There are no warranties, express or implied, including without limitation any warranty of merchantability or
fitness, which extend beyond the description of the face thereof. If the product does not perform as warranted
herein, the purchaser’s sole remedy shall be repair, recalibration, or replacement, at the discretion of Ludlum
Measurements. In no event will Ludlum Measurements be liable for damages, lost revenue, lost wages, or
any other incidental or consequential damages, arising from the purchase, use, or inability to use product.
Return of Goods to Manufacturer
If equipment needs to be returned to Ludlum Measurements, Inc. for repair or calibration, please send to
the address below. All shipments should include documentation containing return shipping address,
customer name, telephone number, description of service requested, and all other necessary information.
Your cooperation will expedite the return of your equipment.
Ludlum Measurements, INC.
ATTN: Radiation Security Division
404 W. 4th St.
Sweetwater, TX 79556
Contact Information
Phone: [phone] (US, CA)
Fax: [phone]
Free Gate Monitor Support
Monday –Friday 8:00 AM –5:00 PM CT
1-800-622-0828 (US, CA)
24 Hours
1-800-717-9506

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Table of Contents
Section 1 - Packaging _______________________________________________________________ 4
Model 4525-7000 __________________________________________________________________________5
Model 4525-10500 _________________________________________________________________________5
Model 4525-14000 _________________________________________________________________________6
Section 2 - Installation _______________________________________________________________ 7
System Buffer Zone ________________________________________________________________________8
Location of Detector 1 and Control Box _____________________________________________________8
Anchoring the Stands ______________________________________________________________________9
Anchor Bolts and Pattern _________________________________________________________________________9
Leveling the Stands _______________________________________________________________________10
Lifting the Stands__________________________________________________________________________11
Squaring the Stands_______________________________________________________________________12
Mounting the Control Box _________________________________________________________________13
Mounting the Remote _____________________________________________________________________13
Mounting the Wall Mounted Computer Kit __________________________________________________13
Wiring and Conduit _______________________________________________________________________13
AC Power Requirements _________________________________________________________________________13
Over Pull for Termination _________________________________________________________________________13
Conduit Requirements___________________________________________________________________________14
Cable Block Diagrams___________________________________________________________________________14
Section 3 –Checklist and Photos for Technician ______________________________________ 15
Installation Checklist______________________________________________________________________15
Photo Requirements ______________________________________________________________________16
Section 4 - Drawings & Diagrams ____________________________________________________ 17

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Section 1 - Packaging
Remove the cardboard and shrink wrap from the pallet (if used) and safely lift each item
on the pallet. Items on the pallet may be secured using metal or plastic strapping. Use
caution, as the strapping may be under tension and can cause injury when cut.
If packed in a crate, remove lid and at least one long side and one short side. Remove all
small items and store in a safe dry place. Safely lift each item one at a time from the crate.
If the items received will not be installed right away, ensure that the pallets or crates are
stored in a dry space as they may contain sensitive electronics that are susceptible to
damage until properly installed.
An envelope containing important information such as calibration certificates, packing
slips, pre-shipment checklist, etc., will be located either in, or attached to the surface of,
the shipment. Remove the envelope and store in a safe place.
Using the provided pre-shipment checklist, ensure all marked items are accounted for. In
the event of a missing item, contact your sales representative immediately to report it and
remediate the issues.

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Model 4525-7000
Without Stands
The system is shipped in one large wooden crate with two detector assemblies containing
all accessories, hardware, and options inside the crate.
The total shipping weight is approximately 680 kg (1500 lb).
With Stands
The system is shipped on two large wooden pallets. Each pallet will contain one stand and
one detector assembly with some accessories already attached. Other accessories,
hardware, and options may also be located loosely inside the stands. At times, a separate
smaller crate will be used to ship accessories ordered with the system.
The total shipping weight is approximately 1905 kg (4200 lb) (includes stand).
Model 4525-10500
Without Stands
The system is shipped in one large wooden crate with three detector assemblies containing
all accessories, hardware, and options inside the crate.
The total shipping weight is approximately 907.2 kg (2000 lb).
With Stands
The system is shipped on two large wooden pallets with larger pallet containing the
overhead frame assembly. Each pallet will contain one stand and one detector assembly
with some accessories already attached. Other accessories, hardware, and options may also
be located loosely inside the stands. At times, a separate smaller crate will be used to ship
accessories ordered with the system.
The total shipping weight is approximately 3719 kg (8200 lb).

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Model 4525-14000
Without Stands
The system is shipped in two large wooden crates with two detector assemblies in each
containing all accessories, hardware, and options inside the crate.
The total shipping weight is approximately 1360 kg (3000 lb).
With Stands (Horizontal Configuration)
The system is shipped on two large wooden pallets. Each pallet will contain one stand and
two detector assemblies with some accessories already attached. Other accessories,
hardware, and options may also be located loosely inside the stands. At times, a separate
smaller crate will be used to ship accessories ordered with the system.
The total shipping weight is approximately 3810 kg (8400 lb).
With Stands (Vertical Configuration)
The system is shipped on four large wooden pallets. Each pallet will contain one stand and
one detector assembly with some accessories already attached. Other accessories,
hardware, and options may also be located loosely inside the stands. At times, a separate
smaller crate will be used to ship accessories ordered with the system.
The total shipping weight is approximately 3810 kg (8400 lb).

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Section 2 - Installation
This section is intended to outline the standard installation of a system and does not cover
actual termination of cables, which is normally performed by Ludlum Measurements, Inc.
(LMI) field service technicians.
The following drawings are provided to facilitate the process in preparing your site for
installation.
Block Diagrams:
517 X 683, 517 X 683A
Model 4525-7000:
517 x 692, 517 X 692A, 517 X 692B, 517 X 692C, 517 X 692D
Model 4525-10500:
517 X 693, 517 X 693A, 517 X 693B, 517 X 693C
Model 4525-14000 (Horizontal):
517 X 695, 517 X 695A, 517 X 695B, 517 X 695C, 517 X 695D
Model 4525-14000 (Vertical):
517 X 694, 517 X 694A, 517 X 562B, 517 X562C

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System Buffer Zone
For best operation, locate the stands in an area where a 3 m (10 ft) buffer zone can be
maintained around the detectors. Typically, the stands are mounted about 3 m (10 ft)
before the weigh scale and never between the start and end of the scale. It is important
that vehicles stay out of this buffer zone except when they are moving slowly between the
detectors. Placing a stop sign at the entrance to this buffer zone is highly recommended.
See Drawings listed below for an aerial view showing the buffer zone.
Model 4525-7000: Drawing 517 x 692B
Model 4525-10500: Drawing 517 x 693B
Model 4525-14000 (Horizontal): Drawing 517 x 695B
Model 4525-14000 (Vertical): Drawing 517 x 692B
Failure to correctly locate the system or failure to enforce the buffer zone may result in
more frequent false alarms. These false alarms are caused by the system having an
incorrect measurement of the true background radiation level before the system is
triggered into check mode.
Location of Detector 1 and Control Box
The back of the stand for detector 1 is the default mounting location for the control box.
Detector 1 should go on the side with the four conduits coming out of the pad. See figure
below for layout example. Systems with three or more detectors will follow the same rule.
To facilitate ease of installation, it is recommended that detector 1 and the control box be
on the side nearest to the location of the monitoring office.
*For representational purposes only. Not drawn to scale.

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Anchoring the Stands
Anchor Bolts and Pattern
For anchor bolt specifications, see Drawing 511 x 836. Due to the close tolerances of the
anchor bolt holes, the anchor bolts must be placed according to the dimensions specified
on the Anchor Bolt Template drawings.
Model 4525-7000: Drawing 511 × 461, 517 x 677
Model 4525-10500: Drawing 511 × 449
Model 4525-14000 (Horizontal): Drawing 384 × 882
Model 4525-14000 (Vertical): Drawing 511 × 461
The anchor bolts should protrude from the concrete from 10 to 12.7 cm (4 to 5 in.).
Note:
LMI recommends the use of an anchor bolt template to ensure the anchor bolts are
placed in the exact locations for your system. These are available to purchase, including
anchor bolt hardware kits, to facilitate installation.
If a template is used, the notch on the template should be placed toward the center of the
lane. The anchor bolt holes are a tight tolerance fit for the ¾-inch anchor bolt; therefore,
care must be taken when the anchor bolts are placed in the concrete. Double-nut the
anchor bolt to the template before the concrete cures to ensure proper anchor-bolt
alignment.

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Leveling the Stands
Once the concrete has cured and all the bolts are straight, the mounting points will need
to be leveled. Shims may be used, but the proper method of using leveling nuts is highly
recommended as described below.
Run a set of leveling nuts on the bolts as low as allowable (one nut per bolt). If the
templates were purchased, place the flat template through the bolts onto the leveling nuts.
Start leveling from the highest nut, using a 0.61 m (2 ft) (or larger) level in the pattern as
demonstrated in the below figures. The stands should be level and plumb within 0.17 cm
(1/16 of an inch) over a 0.61 m (2 ft) distance.

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Lifting the Stands
Note:
LMI recommends the detector assemblies be placed and secured into the stands prior to
lifting the stand into place. If stands were purchased with your system, the detector
assemblies will come pre-assembled with the stands. This can be done by placing the
stand on ground level and using lifting straps to lower the detector assembly into the
stand and securing using the provided hardware.
All stands purchased with your system should include removable lifting eyebolts and
hardware.
Use a lifting harness rated for at least 2268 kg (5000 lbs).
During lifting, the unit will lean towards the back. This will allow you to engage two bolts
first, and then the rest will align as the stand is lowered.
Before removing the lift harness, ensure the stands are securely fastened to prevent injury
or damage.
Before removing the lift harness (and lifting lugs) the four stand mounting nuts will need
to be in place.
Systems with double stacked detectors, ensure the lower stand is securely fastened before
placing the upper stand.
Some systems use legs as risers to mount the stands at the required height. Ensure the
legs are securely fastened before lifting and placing the stand into place.

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Squaring the Stands
After the lower stands have been lifted and secured into place, it is crucial that they are
square with each other. Failure to do so will result in sensor alignment issues that cannot
be resolved with the included sensor mounting brackets.
The opposing front outside corners of the stands should be within 1.27 cm (1/2 of an inch)
of each other on the diagonal reading. Be sure to take the readings at the base of each set
of stands. See the two figures below for an example.

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Mounting the Control Box
The four provided 3/8 x 16-inch stainless steel bolts with a length of 1.9 cm (0.75 in.) should
be used to mount the control box to the back of the stand containing detector 1. Using
bolts longer than the specified may cause damage to the detector assemblies’ enclosure.
Stands purchased with your system will have tapped holes to facilitate the installation of
the control box.
Mounting the Remote
The remote box must be securely attached to the wall using four screws through the
mounting holes on the remote. Refer to Drawing 511 × 207A.
Mounting the Wall-Mounted Computer Kit
The wall-mounted computer kit must be securely mounted using 10 screws through the
mounting holes on the main bracket. Refer to Drawing 396 x 850.
Wiring and Conduit
AC Power Requirements
AC power from the breaker box for the control box must be a minimum #14-gauge wire for
the “hot” and neutral connections, and a #14-gauge wire for the ground connection.
Each system requires a 2-amp power source of 120–240 Vac. LMI recommends a dedicated
and clearly labeled 10-20-amp breaker for each system. AC power should be delivered to
the control box and other system accessories in accordance with local code requirements,
which supersede these instructions. Such requirements, for example, may require a
disconnect device in clear sight of the hard-wired control box.
Over Pull for Termination
All cables must be pulled, leaving a 0.61 m (24 in.) tail past the end of the conduit or cord
grip. Labeling must be used on both ends of the cable to clearly identify each cable. This
can be done using any method, such as color coding, letters, numbers, etc.

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Conduit Requirements
The bottom of each detector enclosure and the control box is pre-drilled for conduit
connections required for a standard installation.
Refer to the following drawings for conduit requirements at the concrete pad.
Model 4525-7000: 517 x 692C
Model 4525-10500: 517 x 693C
Model 4525-14000 (Horizontal): 517 X 695C
Model 4525-14000 (Vertical): 517 x 692C
Note:
All conduit coming out of the concrete up to the enclosures must be flexible Liquid-Tight
Metallic.
Cable Block Diagrams
To facilitate installation, the following drawings are provided to illustrate the required
cables and their routing. These drawings also show conduit and cable requirements for
other standard options available.
Model 4525 1 to 3 Detector Systems: 517 X 683
Model 4525 4 to 6 Detector Systems: 517 X 683A

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Section 3 – Checklist and Photos for Technician
The following checklist and photo requirements will be required to be submitted prior to having
a field service technician scheduled for the on-site commissioning of the system.
Installation Checklist
Yes, No, N/A
Requirement Details
Foundation for detectors is placed where the detectors have a 3 m (10 ft) “buffer zone” in all
directions.
Detectors are installed in approved stands, anchored in concrete, and placed in their proper
configuration.
Stands are diagonally square with one another within 13 mm (0.5 in.).
The control box is mounted on the back of the stand containing detector 1, leaving adequate
space for technicians to perform work safely.
AC power is terminated at the AC power filter terminals. A clearly marked breaker is
accessible in case the AC power must be disconnected.
Detector cables are pulled as shown on the wiring block diagrams provided in this manual
with 61 cm (24 in.) of over pull on each end.
IR sensors are securely mounted using the provided hardware to the stands, at the proper
height and on the correct detector. Receivers will be wired and connected to detector 1,
whereas the transmitters will be wired to detector 2 or 3, depending on the configuration
purchased. See installation drawings for height requirements.
Cat 5e ethernet cable provided is in conduit and pulled from control system to computer
location in office area with 61 cm (24 in.) over pull on each end.
The computer and printer (if used) are in an easily accessible location with proper power
and an uninterrupted power supply installed. If the wall computer kit was purchased, ensure
it has been securely mounted in its desired location to the wall.
The remote annunciator, if purchased, is mounted on the wall in its desired location. The
provided remote cable with 61 cm (24 in.) of over pull on each end must be pulled from the
control box to the remote.
Any additional accessories such as a camera, strobe/horn, traffic light, P2P wireless kit, etc.,
must be installed according to recommended specifications.
For all systems with overhead detectors, or detectors that may not be reached with a 1.8 m
(6 ft) scissor ladder, a man lift and certified operator will be required on site. For all other
systems, a ladder up to 1.8 m (6 ft) will be required for technician’s use to properly inspect
and commission the systems.

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Photo Requirements
No. of Photos
Requirement Details
4 each
System in relation to the scale for perspective and to ensure the 3 m (10 ft) buffer zone is
adequate and enforced.
1 each
Control box mounted on the back side of the stand with detector 1 and height from
ground for easy accessibility.
2 each
Face of each detector, with door closed, showing the placement of all infrared sensors. This
will be detector 1 and detector 2 or 3, depending on your configuration.
1 each
Face of each detector, with doors opened, showing detector cables pulled through
conduits and 61 cm (24 in.) over pull.
1-6 each
Interior of the control box showing the AC power lines terminated, both detector
cables, remote cable, and the Cat-5e network cable with 61 cm (24 in.) over pull.
2-4 each
Optional strobe and horn, camera, wireless P2P kit, and mounted with conduit(s) and
entering the control box.
2-4 each
Location of the computer that will be used for the supervisor software. If using the
wall-mounted computer kit purchased with your system, show kit mounted securely on
the wall with ample room for technician to terminate the connection.
1-2 each
The remote annunciator (if purchased) mounted in its desired location and the remote
cable with 61 cm (24 in.) of over pull past the entrance of the box.
Any
Photos of any additional equipment or peripherals installed and expected to be used in
conjunction with the control box’s hardware or software of the system (gate arms, traffic
lights, etc.).
Any
Show anything else that may be of help for the technician to provide an efficient
commissioning and start-up service, such as barriers, obstacles, or rapid elevation changes
near or around the system, etc.
Submit via email to [e-mail]. Files must be compressed into a single zip file
totaling less than 20 MB.
Please note that delays due to poor validation of these requirements may incur
additional charges at the time of service. For questions, comments, or concerns, send us
an email or give us a call.

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Section 4 - Drawings & Diagrams
Drawing Title
Drawing Number
Model 4525 G3/G5 1-to-3-Detector Dual Channel Block Diagram
517 x 683
Model 4525 G3/G5 4-to-6 Detector Dual Channel Block Diagram
517 x 683A
Model 4525 G5 2-Detector ISO View
517 x 692
Model 4525 G5 2-Detector Elevation
517 x 692A
Model 4525 G5 2-Detector Aerial View
517 x 692B
Model 4525 G5 2-Detector Concrete Plan
517 x 692C
Model 4525 G5 2-Detector Stand
517 x 692D
Model 4525 G5 3-Detector ISO View
517 x 693
Model 4525 G5 3-Detector Elevation
517 x 693A
Model 4525 G5 3-Detector Aerial View
517 x 693B
Model 4525 G5 3-Detector Concrete Plan
517 x 693C
Model 4525 G5 4-Detector Horizontal ISO View
517 x 695
Model 4525 G5 4-Detector Horizontal Elevation
517 x 695A
Model 4525 G5 4-Detector Aerial View
517 x 695B
Model 4525 G5 4-Detector Horizontal Concrete
517 x 695C
Model 4525 G5 4-Detector Horizontal Steel
517 x 695D
Model 4525 G5 4-Detector Vertical ISO View
517 x 694
Model 4525 G5 4-Detector Vertical Elevation
517 x 694A
Model 4525 G5 4-Detector Vertical Lower Stand
517 x 562B
Model 4525 G5 4-Detector Vertical Upper Stand
517 x 562C
Model 4525 Anchor Bolt & Concrete
511 x 836
Model 4525-7000 Conduit Template Guide
517 x 677
Model 4525-7000 Anchor Bolt Template
511 x 461
Model 4525-10500 Anchor Bolt Template
511 x 449
Model 4525-14000 Horizontal Anchor Bolt Template
384 x 882
Model 4525 Remote
511 x 207A
Model 4525 Computer Assembly
396 x 850

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