Teledyne LightHawk 560 User manual
LightHawk®560
Compliance Opacity Monitor
Operations Manual
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SERIAL NUMBER: _____________________
DOCUMENT NO.: 1860-0050-01 REV L
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SEPTEMBER 2011
Proprietary Information. All rights reserved by Teledyne Monitor Labs Inc. No part of this book
may be reproduced or copied in any form or by any means⎯graphic, electronic, or mechanical,
including photocopying, taping, or information storage and retrieval systems⎯without written
permission of the publisher.
Made in the United States of America
LonWorks®is a trademark of the ECHELON Corporation
Patent No. 7,715,009
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TABLE OF CONTENTS Page
1.0 SYSTEM OVERVIEW .................................................................................................................1-1
1.1 System Description, Standard Equipment...................................................................................1-2
1.1.1 Optical Head Assembly ................................................................................................1-2
1.1.2 Retroreflector Assembly................................................................................................1-3
1.1.3 Protective Purge Air System (Single)............................................................................1-3
1.1.4 Enhanced Remote Panel with Multi I/O Board..............................................................1-3
1.1.5 Calibration Kit................................................................................................................1-4
1.1.6 Attenuators....................................................................................................................1-4
1.2 Specifications (Standard System) ...............................................................................................1-4
1.3 Measurement Units .....................................................................................................................1-7
1.3.1 Correction for Exit Path Length.....................................................................................1-8
1.4 Safety...........................................................................................................................................1-8
2.0 OPTIONAL EQUIPMENT............................................................................................................2-1
2.1 Protective Purge Air System (Dual).............................................................................................2-1
2.2 Weather Cover, Retro..................................................................................................................2-1
2.3 Purge Shutter Assemblies...........................................................................................................2-1
2.4 Instrument Air Purge....................................................................................................................2-1
2.5 High Efficiency Purge Air Filtration System.................................................................................2-1
2.6 Hinged Fiberglass Weather Covers ............................................................................................2-2
2.7 Purge Air Heater..........................................................................................................................2-2
2.8 Optical Head Dust Cover.............................................................................................................2-2
2.9 High Temperature Operation.......................................................................................................2-2
2.10 Heat Shield................................................................................................................................2-2
2.11 Pressure and Temperature Input Interface ...............................................................................2-3
2.12 Optical Head Transport Cover...................................................................................................2-3
2.13 Alignment Scope, Mounting Flange ..........................................................................................2-3
3.0 OPTICAL HEAD ASSEMBLY......................................................................................................3-1
3.1 Overview .....................................................................................................................................3-1
3.2 Mechanical Description ...............................................................................................................3-1
3.3 Optical Description ......................................................................................................................3-1
3.4 Electrical Description...................................................................................................................3-2
3.4.1 AC Power Connections.................................................................................................3-2
3.4.2 Signal Processing Electronics.......................................................................................3-3
3.4.3 Simulated Zero/Upscale Device Drive Components.....................................................3-3
3.5 User Interface Description...........................................................................................................3-4
3.5.1 Six Character LED Display............................................................................................3-4
3.5.2 Key Pad.........................................................................................................................3-4
3.5.3 Status LEDs..................................................................................................................3-7
3.5.4 Data and Parameter Location Definitions.....................................................................3-7
4.0 ENHANCED REMOTE PANEL WITH MULTI I/O MODULE.......................................................4-1
4.1 Overview .....................................................................................................................................4-1
4.2 Mechanical Description ...............................................................................................................4-1
4.3 Electrical Description...................................................................................................................4-2
4.3.1 Input Power Requirement .............................................................................................4-2
4.3.2 Circuit Description (Overview).......................................................................................4-2
4.4 Operational Description.............................................................................................................4-13
4.4.1 Main Display Screen...................................................................................................4-13
4.4.2 Main Menu Screen......................................................................................................4-16
4.4.3 Service Data Menu......................................................................................................4-16
4.4.4 View Service Data.......................................................................................................4-16
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TABLE OF CONTENTS
(Continued)
Page
4.4.5 View Head Mode.........................................................................................................4-16
4.4.6 View Audit Data...........................................................................................................4-16
4.4.7 Change Attenuator Values..........................................................................................4-17
4.4.8 Clear Audit Data..........................................................................................................4-17
4.4.9 Status Codes Help......................................................................................................4-17
4.4.10 Output & Cal Tests....................................................................................................4-18
4.4.11 Output Module Configuration Menu..........................................................................4-18
4.4.12 Analog Outputs 1,2 ...................................................................................................4-19
4.4.13 Analog Outputs 3,4 ...................................................................................................4-19
4.4.14 Relay Assignments ...................................................................................................4-20
4.4.15 System Properties Menu...........................................................................................4-20
4.4.16 Change STP Ref Points............................................................................................4-20
4.4.17 View System Properties............................................................................................4-21
4.4.18 View Optics & Cal Properties....................................................................................4-21
4.4.19 Change Cal Properties..............................................................................................4-21
4.4.20 Change Optics Properties.........................................................................................4-22
4.4.21 Change System Properties.......................................................................................4-22
4.4.22 Change Password.....................................................................................................4-23
4.4.23 Change Opacity Set Points.......................................................................................4-23
4.4.24 Change Other Set Points..........................................................................................4-23
4.4.25 View Part. Mass Points.............................................................................................4-24
4.4.26 Change Part. Mass Curve.........................................................................................4-24
4.4.27 Display Properties Menu...........................................................................................4-25
4.4.28 View Alarm Set Points...............................................................................................4-25
4.4.29 View Trending Data...................................................................................................4-26
4.4.30 Trend Screen, Instantaneous Opacity ......................................................................4-26
4.4.31 View Numerical Data.................................................................................................4-26
4.4.32 View Status History...................................................................................................4-27
4.4.34 View Alarms History..................................................................................................4-27
5.0 PURGE SYSTEM OVERVIEW....................................................................................................5-1
5.1 Mechanical Description ...............................................................................................................5-1
5.2 Electrical Description...................................................................................................................5-1
5.3 Operation.....................................................................................................................................5-2
5.4 Purge Status................................................................................................................................5-2
5.5 Dual Protective Purge Air System (Dual) Blower Option ............................................................5-2
5.6 Purge Shutter Assembly Option..................................................................................................5-2
5.7 Instrument Air Purge Option........................................................................................................5-3
6.0 CALIBRATION KIT OVERVIEW..................................................................................................6-1
6.1 Operation.....................................................................................................................................6-1
6.2 Storage........................................................................................................................................6-2
7.0 MAINTENANCE & ON-STACK CALIBRATION..........................................................................7-1
7.1 Routine Maintenance...................................................................................................................7-1
7.2 On-Stack Calibration ...................................................................................................................7-5
7.2.1 Procedure for On-Stack Calibration Checklist ..............................................................7-5
7.3 Attenuator Audit.........................................................................................................................7-12
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TABLE OF CONTENTS
(Continued)
Page
8.0 OFF-STACK CALIBRATION.......................................................................................................8-1
8.1 Factory Selection of Optical Elements ........................................................................................8-1
8.2 Generating an Optical Clear Path Opacity Signal.......................................................................8-2
8.2.1 Simulating Installation Path Length on Test Stands.....................................................8-2
8.2.2 Actual Clear Path Conditions........................................................................................8-3
8.3 Across Stack Alignment...............................................................................................................8-3
8.3.1 Optical Head Assembly.................................................................................................8-3
8.3.2 Retroreflector Assembly................................................................................................8-4
8.4 Cleaning the Optical Surfaces.....................................................................................................8-5
8.4.1 Cleaning Materials ........................................................................................................8-5
8.4.2 Cleaning Procedures.....................................................................................................8-6
8.5 Optical Head Zero and One Hundred Percent Opacity...............................................................8-7
8.5.1 Setting the LED Current Level ......................................................................................8-7
8.5.2 Setting the Signal Gain .................................................................................................8-9
8.5.3 Final Calibration SET Function Routines....................................................................8-10
8.6 Adjusting Calibration Kit ............................................................................................................8-15
8.7 Verify the Response of the Optical Head..................................................................................8-17
8.8 Cal Mechanism Neutral Density Window Replacement............................................................8-17
8.9 Cal Kit Neutral Density Window Replacement..........................................................................8-19
8.10 Off-Stack Calibration History...................................................................................................8-21
9.0 INSTALLATION...........................................................................................................................9-1
9.1 Flange Mounting..........................................................................................................................9-1
9.1.1 Mounting Pipe Considerations........................................................................................9-1
9.2 Distance Determination...............................................................................................................9-3
9.3 Power Requirements...................................................................................................................9-4
9.4 Purge Air System.........................................................................................................................9-4
9.5 Data Cable...................................................................................................................................9-4
9.6 Purge Cable.................................................................................................................................9-4
9.7 Mounting the Optical Head and Retro Assemblies .....................................................................9-4
9.8 Enhanced Remote Display Assembly.........................................................................................9-5
10.0 TROUBLESHOOTING ............................................................................................................10-1
10.1 Primary Status Code U3..........................................................................................................10-1
10.2 Extended Status Code U4.......................................................................................................10-2
10.3 Assistance ...............................................................................................................................10-2
APPENDIX A SITE SPECIFICATION DATA SHEETS
APPENDIX B MAINTENANCE CHECK SHEETS
APPENDIX C SPARE PARTS
APPENDIX D DRAWINGS
Drawing No. Sheet Rev Description
1800-0007 1 of 7 J LightHawk®560 Opacity w/Instr. Air System Installation
1800-0007 2 of 7 J LightHawk®560 Opacity Single Blower System
Installation
1800-0007 3 of 7 J LightHawk®560 Opacity Dual Blower System Installation
1800-0007 4 of 7 J LightHawk®560 Dual Blower Hi-Temp System
Installation
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