LUDLUM 4525-7000 User manual

LUDLUM MODELS
4525-2400
4525-7000
4525-10500
4525-14000
4525-17500
4525-21000
RADIATION PORTAL MONITOR
INSTALLATION MANUAL
October 2018
Serial Number GM5179 and Succeeding
Serial Numbers

LUDLUM MODELS
4525-2400
4525-7000
4525-10500
4525-14000
4525-17500
4525-21000
RADIATION PORTAL MONITOR
INSTALLATION MANUAL
October 2018
Serial Number GM5179 and Succeeding
Serial Numbers

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.
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: REPAIR DEPARTMENT
501 OAK STREET
SWEETWATER, TX 79556
866-420-9732 325-235-9732
FAX [phone]
PORTAL MONITOR TECH SUPPORT 800-717-9506 (24 hours) or 325-235-9732

DESIGNER AND
MANUFACTURER
OF
Scientific and Industrial
Instruments
LUDLUM MEASUREMENTS, INC.
501 OAK STREET
P.O. BOX 810
SWEETWATER, TEXAS 79556
WEBSITE: WWW.LUDLUMS.COM
866-420-9732(US & CANADA) 325-235-9732 325-235-8768(FAX) Email: [email protected]
Ludlum Model 4525 Site Preparation Checklist
In order to facilitate the installation of your Model 4525, please complete the following checklist and return it to us
via fax or email. This checklist will need to be returned to Ludlum Measurements before our technician can
commence travel to your location. Please be aware that there will be additional charges if our technician is delayed in
completing the installation due to a lack of site preparation.
COMPLETED?
Yes No Site Preparation Requirement
Foundations placed in location where detectors have a 10 foot (3 m) “buffer zone” in all
directions, and where trucks will be able to drive slowly through the system without stopping.
System may have frequent false alarms if this step is ignored.
On all overhead installations, the customer will provide a man lift to work on the overhead
detector. If the customer does not provide one, our technician will rent one at the expense of the
customer. Any additional time cost will be charged to the customer.
Detectors mounted in stand, and stands in place on either side of vehicle path, generally before
the weigh scale. Stands are diagonally square with each other within 0.5 inch.
Control box mounted on the back of master detector (#1) stand.
120-240 VAC electricity with separate breaker run in separate conduit to control box enclosure.
Breaker identified and tagged.
Conduit installed and detector cable (100-foot (30 m) roll of Belden 8774, 9 pair) between each
primary detector and control box, leaving 24 inches over pull. For systems with more than 2
detectors, pull cable and run conduit between the primary and secondary detectors as well.
Conduit installed and Cat5e cable pulled from control box enclosure to inside of building near
where the wall-mount computer will be mounted.
Infrareds: Mount 4 receiver assemblies to Detector # 1 stand in the location specified by the
label attached to each assembly. Mount 4 transmitter assemblies to the opposite side.
Wall-mount computer mounted on office wall-or at least the spot located and cleared off, ready
for mounting.
Remote display mounted with conduit installed and cable (100-foot (30 m) default roll Belden
9946, 10 conductors) pulled.
Camera, remote display, or additional strobe/horn options (if ordered) to be mounted, with
conduit run as necessary.
Customer will make a 6 foot (1.8 m) ladder available to the technician on site.
If installing overhead detectors, the customer must have an OHSA certified individual present
for the on-site installation.
Signature/Date: __________________________________________________
Company: ______________________________________________________
October 2014

Ludlum Measurements, Inc. October 2018
Table of Contents
Overview 1
Detector Stand Installation 2
Shipping Crates 2-1
Stand Location – Buffer Zone 2-7
Stand Orientation 2-7
Typical Stand Setup 2-8
Setting Up The Stands 2-8
Anchor Bolts and Pattern 2-8
Conduit Requirements 2-14
Control Box 2-14
Cable Requirements 2-14
Control Box Wiring 2-15
Detector Wiring 2-16
Remote Display 2-17
Cat-5E LAN Cabling 2-17
Supervisor Computer 2-18
Miscellaneous Requirements 2-18
Software and Network Installation 3
Software Installation 3-1
Network Installation 3-2
Software License Agreement 3-9
Drawings and Diagrams 4

Model 4525 Radiation Portal Monitor Installation Manual Section 1
Ludlum Measurements, Inc. Page 1-1 October 2018
Overview
The Ludlum Model 4525 Radiation Portal Monitor or “gate monitor” is designed
to detect very low levels of radiation, typically in vehicle loads as they are driven
between the detectors. Usually the radiation detectors are placed right before a
weigh scale. This manual is intended to assist you in the installation of the system.
Several different models and options are available. In general, the full model
number tells the number of detectors – the Model 4525-7000 is a two-detector
system, the Model 4525-10500 is a three-detector system, and the 4525-14000
system has four detectors. Each detector contains approximately 57,355 cm3(3500
cubic inches) of plastic scintillator. These are also other systems available, like the
Model 4525-2400, which has four 9832 cm3(600 in3) detectors.
The detectors are normally mounted to the side of the vehicle, and also sometimes
above the vehicle. The detectors are centered around the typical load; your situation
or location might require the detectors to be higher or lower than the dimensions
shown in the back of this manual.
Each system comes with a wall-mount computer display, printer, and universal
power supply (UPS). This computer logs data and displays the current status of the
system. It is typically placed inside the scale house, or in close proximity to the scale
operator. A remote display, with status lights and a reset button, is also provided.
The remote can show the status and allow someone to reset alarms whenever the
main computer is inaccessible. It is typically placed in the scale house, or sometimes
under a weather-protected porch.
Each system uses infrared sensors to detect the vehicle’s presence, and thus switch
from measuring the background radiation to checking for an alarm. Multiple sets of
sensors are used to measure the speed of the vehicle and to ensure that the vehicle
presence is sensed throughout the passage of the vehicle. The range of vehicle sizes,
from flatbed trailers to tall drop-off boxes, necessitates some care in positioning the
sensors. The drawings in the back of the manual suggest some mounting heights
that have worked at many locations.
Take a moment to review the block diagrams that are located at the back of this
manual (Drawings 511 x 420 and 511 x 420A). Compare those drawings with the
system that you have purchased or are about to purchase. The block diagram may
help you to understand the available options. You can also use the block diagram to
locate where at your location the different components will be situated.
Section
1

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-1 October 2018
Detector Stand Installation
This procedure is intended to outline the stand installation of the Ludlum Model
4525-2400, 4525-7000, Model 4525-10500, and Model 4525-14000 Radiation
Detection Systems. It does not cover actual termination of cables, which is
normally performed by Ludlum Measurements, Inc. (LMI) technicians. The stand
installation covers the following items:
1) Shipping Crates
2) Stand Location – Buffer Zone
3) Stand Orientation
4) Typical Stand Setup
5) Setting Up The Stands
6) Conduit Requirements
7) Cable Requirements
8) Remote Display
9) CAT-5E LAN Cabling
10) Supervisor Computer (optional)
11) Monitor Computer (optional)
12) Miscellaneous Requirements
Note:
Drawings of the model numbers listed above are located in the back of
this manual. Before building and installing the stands, please review the
drawings of the Model 4525 that you have ordered to assist in the
installation process.
Shipping Crates
Each system may be purchased with or without the steel stands that provide
protection to the radiation detectors. Purchase of the steel stands from Ludlum
Measurements, Inc. facilitates the installation process. The following lists the
contents of the shipping crates.
Section
2

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-2 October 2018
CRATE CONTENTS OF THE MODEL 4525-2400 WITHOUT STANDS
The system is shipped I one crate, containing:
•Four white PVC pipe detectors (Model 44-128-9), 152 x 12.7 x 5 cm (60
x 5 x 2 in.) each
•Two junction boxes
•One 30.5 m (100 ft) roll of cable for the detectors (Belden 8774 or
equivalent)
•One 76.2 m (250 ft) roll of CAT-5E cable for Ethernet connection
(Belden 1501A or equivalent)
•One remote display with 30.5 m (100 ft) cable (Belden 9946 or
equivalent)
•One white control box enclosure
•If a computer is purchased with the system, it will be inside the crate.
•Eight infrared components with conduit
•Any other optional items will be packed in the crate with the detectors.
•The total shipping weight of the crate is approximately 408 kg (900 lb).
CRATE CONTENTS OF THE MODEL 4525-7000 WITHOUT STANDS
The system is shipped in one crate, containing:
•Two large (approximately 2.1 x 2.1 x 0.25 m {7ft x 2 ft x 10 in.}) white
detector boxes labeled Detector 1 and Detector 2
•One 30.5 m (100 ft) roll of cable for the detectors (Belden 8774 or
equivalent)
•One 76.2 m (250 ft) roll of CAT-5E cable for Ethernet connection
(Belden 1501A or equivalent)
•One remote display with 30.5 m (100 ft) cable (Belden 9946 or
equivalent)
•One white control box enclosure
•If a computer is purchased with the system, it will be inside the crate.
•Eight infrared components with conduit
•Any other optional items will be packed in the crate with the detectors.
•The total shipping weight of the crate is approximately 680 kg (1500 lb).

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-3 October 2018
CRATE CONTENTS OF THE MODEL 4525-10500 WITHOUT STANDS
The system is shipped in two crates.
The first crate contains: Detector 1 and Detector 2.
The second crate contains: Detector 3.
•One 30.5 m (100 ft) roll of cable for the detectors (Belden 8774 or
equivalent)
•One 76.2 m (250 ft) roll of CAT-5E cable for Ethernet connection
(Belden 1501A or equivalent)
•One remote display with 30.5 m (100 ft) cable (Belden 9946 or equivalent)
•One white control box enclosure
•If a computer is purchased with the system, it will be inside the crate.
•Eight infrared components with conduit
•Any other optional items will be packed in the crate with the detectors.
•One crate is approximately 635 kg (1400 lb), and the other is
approximately 454 kg (1000 lb).
CRATE CONTENTS OF THE MODEL 4525-14000 WITHOUT STANDS
The system is shipped in two crates, containing:
•Four large white detector boxes labeled Detector 1, 2, 3, and 4
•One 30.5 m (100 ft) roll of cable for the detectors (Belden 8774 or
equivalent)
•One 76.2m (250 ft) roll of CAT-5E cable for Ethernet connection
(Belden 1501A or equivalent)
•One remote display with 100 foot cable (Belden 9946 or equivalent)
•One white control box enclosure
•If a computer is purchased with the system, it will be shipped inside the
crate that contains Detector 1.
•Any other optional items will be packed in the crate with the detectors.
•The total shipping weight of each crate is approximately 680 kg (1500 lb).

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-4 October 2018
PALLET CONTENTS OF THE MODEL 4525-2400 WITH STANDS
Each pallet contains …
•One 30.5 m (100 ft) roll of cable for the detectors (Belden 8774 or
equivalent)
•One 76.2 m (250 ft) roll of CAT-5E cable for Ethernet connection
(Belden 1501A or equivalent)
•One remote display with 100 foot cable (Belden 9946 or equivalent)
•Eight infrared components with conduit
•If a computer is purchased with the system, the computer and white
control box enclosure will be shipped in smaller crates strapped to the
pallet.
•The total shipping weight of the two pallets is approximately 744 kg (1640
lb) (includes stand).
PALLET CONTENTS OF THE MODEL 4525-7000 WITH STANDS
Each pallet contains a large yellow detector stand with a large white detector box
mounted inside the stand. Pallet 1 holds detector 1. The following items are
strapped onto the pallet with Stand # 1.
•One 30.5 m (100 ft) roll of cable for the detectors (Belden 8774 or
equivalent)
•One 76.2 m (250 ft) roll of CAT-5E cable for Ethernet connection
(Belden 1501A or equivalent)
•One remote display with 100 foot cable (Belden 9946 or equivalent)
•Eight infrared components with conduit
•If a computer is purchased with the system, the computer and white
control box enclosure will be shipped in smaller crates strapped to the
pallet.
•The total shipping weight of the two pallets is approximately 1905 kg
(4200 lb) (includes stand).

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-5 October 2018
PALLET CONTENTS OF THE MODEL 4525-10500 WITH STANDS
The system comes in three pallets. The two smaller pallets contain a large yellow
detector stand with a large white detector box mounted inside the stand. The large
pallet contains a large yellow detector stand and white detector box attached to the
overhead mounting frame. Also strapped to the large pallet are the mounting legs
to suspend the overhead frame over the scale or lane. Pallet 1 holds Detector 1,
Pallet 2 holds Detector 2 and the overhead holds Detector 3. The following items
are strapped onto the pallet with Stand # 1:
•One hardware mounting kit containing the following:
Qty 32 ¾ in. x 3-inch long hex bolts
Qty 32 ¾ in. hex nuts
Qty 32 ¾ in. lock washers
Qty 32 ¾ in. flat washers
•One 30.5 m (100 ft) roll of cable for the detectors (Belden 8774 or
equivalent)
•One 76.2 m (250 ft) roll of CAT-5E cable for Ethernet connection
(Belden 1501A or equivalent)
•One remote display with 30.5 m (100 ft) cable (Belden 9946 or
equivalent)
•Eight infrared components with conduit
•If a computer is purchased with the system, it will be shipped in with the
pallet.
•One white control box enclosure
•Any other optional items will be strapped on the pallet
•The total shipping weight of the three pallets is approximately 3719 kg
(8200 lb) (includes stand).

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-6 October 2018
PALLET CONTENTS OF THE MODEL 4525-14000 WITH STANDS
(INCLUDING 1CRATE)
The system comes in three pallets. Each pallet contains one large, yellow detector
stand with two large, white detector boxes mounted inside the stand. Pallet 3
contains the four each I-beam legs for mounting the stands. The crate contains:
•One hardware mounting kit containing the following:
Qty 16 ¾ x 3 in. long hex bolts
Qty 16 ¾ in. hex nuts
Qty 16 ¾ in. lock washers
Qty 16 ¾ in. flat washers
•One 30.5 m (100 ft) roll of cable for the remote (Belden 9946 or
equivalent)
•One 76.2 m (250 ft) roll of CAT-5E cable for Ethernet connection
(Belden 1501A or equivalent)
•One 30.5 m (100 ft) roll of cable for the detectors (Belden 8774 or
equivalent)
•One white control box enclosure
•Eight infrared components with conduit
•If a computer is purchased with the system, it will be shipped in the crate.
•Any other optional items will be strapped to the crate.
•The shipping weight of pallets 1 and 2 is approximately 1814 kg (4000 lb)
each (includes stands).
•Weight of the third pallet is approximately 249 kg (550 lb) Weight of the
crate is approximately 318 kg (700 lb)
UNPACKING
1) Remove the cardboard and shrink wrap from the stand.
2) Remove the peripherals from the crate. Store the peripherals in a safe
location.
3) On Model 4525-10500 and Model 4525-14000, remove the I-beam
legs and keep them accessible for preassembly.

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-7 October 2018
Stand Location – 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. 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 recommended, as well as painting a line
on the pavement. See Drawing 511 x 718A for Model 4525-2400, Drawing 511 x
375 for Model 4525-7000, Drawing 511 x 439 for Model 4525-10500, and
Drawing 511 x 376 for Model 4525-14000 in the back of this manual. Failure to
correctly locate the system or failure to enforce the buffer zone will result in more
frequent false alarms. These false alarms are caused by the system having an
incorrect measurement of the true background radiation level.
Stand Orientation
Detector 1 has the control box mounted to its stand. Detector 1 should go on the
side with the four conduits coming out of the pad. See figure below for layout.
MODELS 4525-2400 AND 4525-7000
MODEL 4525-10500

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-8 October 2018
MODEL 4525-14000
Typical Stand Setup
To see a typical installation of the gate monitors, see the following drawings:
Model 4525-2400: Drawings 511 x 718 through 511 x 718C
Model 4525-7000: Drawings 511 x 375 through 511 x 375C
Model 4525-10500: Drawings 511 x 439 through 511 x 439C
Model 4525-14000: Drawings 511 x 376A through 511 x 376D
Setting up the Stands
ANCHOR BOLTS AND PATTERN
For anchor bolt specifications, see Drawing 511 x 836, which is the second to last
drawing in Section 4 Drawings & Diagrams at the end of this manual. 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
(The anchor bolt drawings listed below are listed in an index at the beginning of
Section 4. An anchor bolt template is listed at the end of almost every system.):
Models 4525-2400 and 4525-7000 = Drawing 511 × 461
Model 4525-10500 = Drawing 511 × 449
Model 4525-14000 = Drawing 384 × 882
The anchor bolts should protrude from the concrete from 10 to
12.7 cm (4 to 5 in.).

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-9 October 2018
Note:
LMI recommends the use of a template to be sure the anchor bolt
holes are placed in the correct locations. These can be supplied by
LMI. The part numbers are:
Models 4525-2400 and 4525-7000 template part number 7511-461 (2
each needed)
Model 4525-10500 template part number 7511-449 (2 each needed)
Model 4525-14000 template part number 7384-882 (2 each needed)
The notch on the templates 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.
LEVELING
1) Once the concrete is dry and all the bolts are straight, the mounting points
will need to be leveled. Shims may be used, but the following instructions assume
the use of leveling nuts.
2) Run a set of leveling nuts on the bolts as low as allowable (one nut per
bolt).
3) Place the flat template for the concrete holes on the leveling nuts.
4) Start leveling from the highest nut, using a 0.61 m (2 ft) (or larger) level in
the pattern described below. The stands should be level and plumb within 0.17 cm
(1/16 of an inch) over a 0.61 m (2 ft) distance.

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-10 October 2018
Models 4525-2400, 4525-7000, and 4525-10500 Individual Stand Leveling
Model 4525-14000 Individual Stand Leveling

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-11 October 2018
LIFTING
Models 4525-2400 and 4525-7000
1) All stands should be equipped with removable lifting lugs attached to
the top of the stands. Use a lifting harness rated for at least 1361 kg
(3000 lb).
2) 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 (provided care was used in placing the bolts).
3) Before removing the lift harness (and lifting lugs) the four stand-
mounting nuts will need to be in place.
Model 4525-10500
1) Remove the lifting lugs from the individual big yellow boxes and
install them into the top of the overhead stand legs. The top is the
end with the gusset beams. Use a lifting harness rated for at least 1361
kg (3000 lb).
2) Raise the legs and set them into place on the anchor bolts in the
concrete pad. Secure them into place. Remove lifting lugs. To lift the
overhead frame, use TWO lifting harnesses, each rated for at
least 1361 kg (3000 lb). Wrap one harness around the beams and
against the end of the yellow box. Wrap the other the same way on
the other end of the yellow box. Hook into both straps to lift. Set the
overhead into position, attach all screws, and securely tighten.
3) Replace the lifting lugs into the lower-stand, yellow boxes. Tighten
securely.
4) During lifting of the lower stands, the stands 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 (provided care was used in placing the
bolts).
5) Before removing the lift harness (and lifting lugs) the four stand mounting
nuts will need to be in place.

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-12 October 2018
Model 4525-14000
1) Be sure that the I-beam legs are attached before lifting.
2) All stands should be equipped with removable lifting lugs attached to
the top of the stands. Use a lifting harness rated for at least 2268 kg
(5000 lb). Be sure to attach harness(es) to all four lifting lugs. Two lugs
are not strong enough to support the weight of the stand.
3) Before removing the lift harness (and lifting lugs), the stand mounting
nuts will need to be in place.
TORQUE SPECS FOR ¾-INCH BOLTS/NUTS (NOT SUPPLIED)
1) Grade 2 = 155 ft-lbs
2) Grade 3 (or 100,000 PSI Stainless Steel ) = 234 ft-lbs.
3) Grade 5 = 257 ft-lbs
4) Grade 8 = 380 ft-lbs.
SQUARING
The opposing front outside corners of the stands should be within a half-inch of
each other on the diagonal reading. Be sure to take the readings at the base of each
set of stands (see figures on the following page).

Model 4525 Radiation Portal Monitor Installation Manual Section 2
Ludlum Measurements, Inc. Page 2-13 October 2018
MODELS 4525-2400, 4525-7000,AND 4525-10500 DIAGONAL SQUARING
MODEL 4525-14000 DIAGONAL SQUARING