Page 1 LightHawk 560 Compliance Opacity Monitor Operations Manual...
Page 2 (This page intentionally left blank.)
Page 3 SERIAL NUMBER: _____________________ DOCUMENT NO.: 1860-0050-01 REV K...
Page 4 JANUARY 2008 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.
Page 5: Table Of Contents
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 ....................1-2 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 ........................
Page 6 TABLE OF CONTENTS (Continued) Page 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 ....................
Page 7 LightHawk 560 Opacity Dual Blower System Installation 1800-0007 4 of 7 LightHawk 560 Dual Blower Hi-Temp System Installation 1800-0007 5 of 7 LightHawk 560 Single Blower, Dual Covers System Installation 1800-0007 6 of 7 LightHawk 560 Single Blower, Dual Covers Hi-Temp System Installation...
Page 8 TABLE OF CONTENTS (Continued) Drawing No. Sheet Description 1800-0007 7 of 7 LightHawk 560 Opacity Dual Covers w/Instr. Air System Installation 1800-0013 1 of 2 LightHawk 560 Opacity Monitor Flange Mtg. Methods 1800-0013 2 of 2 LightHawk 560 Opacity Monitor Flange Mtg. Methods...
Page 9: System Overview
Enhanced Remote Panel Calibration Kit Assembly As shown on the LightHawk 560 Installation Drawing, the first 3 are located on the stack. The Enhanced Remote Panel Assembly is located in the Control Room. A Calibration Kit and Filter Pouch are also provided.
Page 10: System Description, Standard Equipment
Optical Head Assembly. It is mounted in a cast aluminum housing which is “O” ring sealed and connected to the Protective Purge Air System to prevent contamination of the optical surface. SEC 1 LIGHTHAWK 560 OVERVIEW.DOC...
Page 11: Protective Purge Air System (Single)
External connection to the Ethernet Module is made via a standard RJ45 connector socket in the rear panel of the ERP. The module will provide web browser-based remote access, configuration and control of the LightHawk 560. At the same time the Ethernet Module can provide HTML web pages for user interface and fast Modbus TCP access to instrument data and parameters.
Page 12: Attenuators
Stability Over Operating Temperature Range ±2.0% Opacity Maximum per 40 F (22.2 change in temperature (as per ASTMD6216) Stability Over Operating Mains Voltage Range ±1.0% Opacity Maximum (as per ASTMD6216) Mean Time Between Failure 8300 Hours (Estimated) SEC 1 LIGHTHAWK 560 OVERVIEW.DOC...
Page 13 9600 Data Bits Stop Bits Parity Type No Parity Connector Designation & Type J16, DB9 RS422/RS485 Port Configuration BAUD Rate 9600 Data Bits Stop Bits Parity Type No Parity Connector Designation & Type J17, DB15 SEC 1 LIGHTHAWK 560 OVERVIEW.DOC...
Page 14: Measurement Units
OPACITY = 1 - TRANSMITTANCE Where opacity and transmittance are expressed as a decimal For a CLEAR PATH condition: TRANSMITTANCE = 100% OPACITY = 0% For a BLOCKED STACK condition: TRANSMITTANCE = 0% OPACITY = 100% SEC 1 LIGHTHAWK 560 OVERVIEW.DOC...
Page 15: Correction For Exit Path Length
These outputs can be configured only after comprehensive source testing is performed at the user's site. Simultaneous collection of the LightHawk 560 attenuation data and gravimetric analysis of the particulate mass of the stack effluent must be performed over a wide range of particulate mass conditions in order to generate a correlation curve.
Page 16: Safety
1.4 SAFETY This equipment is intended only for the purposes specified in this manual. Safety protections inherent in this equipment may be impaired if the LightHawk 560 is used in a manner different than specified herein. The following are internationally recognized symbols used on the LightHawk 560 along with specific cautions applicable to the equipment.
Page 17: Optional Equipment
2.6 PRESSURE AND TEMPERATURE INPUT INTERFACE The Analo g Input Interface Module is used when the stack temperature and pressure data must be input to the LightHawk 560 to correct Particulate Mass to standard conditions. The user must supply the 4-20mA signals to the module...
Page 18: Alignment Scope Mounting Flange
2.11 PURGE AIR HEATER The LightHawk 560 Purge Air Heater option is offered only to those customers whose measured gas stream contains high moisture content with a dew point below the typical purge air temperature. In some rare cases, the inclusion of the relatively cool purge air may cause the stack water vapor to condense at the interface between the purge air and the stack effluent.
Page 19: Optical Head Assembly
Optical Section may be swung to the right to fully access this area. 3.3 OPTICAL DESCRIPTION The LightHawk 560 uses a solid state light source (LED). The projected light intensity is monitored by a reference detector and maintained constant by control circuitry.
Page 20: Electrical Description
AC power connections from user supplied circuits are made to the Integral Junction Box located on the bottom of the Optical Head Assembly. Terminals for the network communication wiring between the Optical Head Assembly and peripheral devices are also located in this Integral Junction Box. SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 21: Signal Processing Electronics
Connection Pin Header Connector SIX POINT I/O BOARD SBC332 (Optional) Motor BOARD 2 Discrete 2 Relay 2 4-20mA Network Isolator Outputs Analog Outputs (to Enhanced Inputs Remote Display) MAINS JUNCTION BOX VOLTAGE FIGURE 3-2 SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 22: User Interface Description
When pressed by itself while a data field is currently displayed, there is no effect. When pressed and held simultaneously with "CAL", ‘NORMAL”, "ZERO" or "BACKGND" keys, a “SET” function is initiated for each respective mode key. SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 23 LED display between U2 (Selectable Average) and F4 (Audit Marker). 3.5.2.2 Combinations of Keys SET*ZERO: Initiates a ZERO SET function. SET*BACKGND: Initiates a BACKGROUND SET function. SET*NORMAL: Initiates a Clear Stack SET. UPSCALE*ZERO: Initiates a complete Calibration Cycle. SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 24 F4 at the time of button actuation. If F4=13XX, it is Filter Run #1 High Filter; if F4=23XX, it is Filter Run #2 High Filter; and so on. The user must press “SET” after SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 25: Status Leds
" key until the second character increments to the number "2" The value of the data in location U2 will be displayed on the RED 4 digit display to the right of the location identifier. SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 26 User Data Bank. The following are the definitions of the data contained in the U BANK locations: Instantaneous Opacity {Optical Density}[Particulate Mass] 1 Minute Average Opacity {Optical Density}[Particulate Mass] Selectable Average Opacity {Optical Density}[Particulate Mass] SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 27 U4. X X 1 X= Excessive DUST Compensation X X X 4 = UPSCALE Calibration bad X X X2 = ZERO Calibration bad X X X 1 = ZERO SET voltage out of range SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 28 1XXX = Run #1 and Initial Zero 2XXX = Run #2 3XXX = Run #3 4XXX = Run #4 5XXX = Run #5 and Final Zero Last ZERO Calibration {ZERO Optical Density}[ZERO Particulate Mass] 3-10 SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 29 Optical Head Temperature, °C Calibration Mechanism Position +15V Power Supply Voltage (+/-5%) -15V Power Supply Voltage (+/-5%) +5VA (analog) Power Supply Voltage (+/-5%) -5VA (analog) Power Supply Voltage (+/-5%) +5VD (digital) Power Supply Voltage (+/-5%) SEC 3 LIGHTHAWK 560 OPT HD.DOC 3-11...
Page 30 ZERO SCALE = 1, 6PIO AO’s to TEST MID SCALE = 2 , 6PIO AO’s to TEST FULL SCALE = 3) Service Marker (Normal Data = 0, Out of Service = 1) PLCF (Factory setting, not user adjustable) 3-12 SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 31 Seconds of ZERO (In Calibration Automatic Daily Cycle) Seconds of UPSCALE (In Calibration Automatic Daily Cycle) Seconds of PLCF (In Calibration Automatic Daily Cycle) Seconds of DUST COMP (In Calibration Automatic Daily Cycle) SEC 3 LIGHTHAWK 560 OPT HD.DOC 3-13...
Page 32 Y1, Output Point #1, Particulate Mass, mg/m^3 X2, Input Point #2, Optical Density Y2, Output Point #2, Particulate Mass, mg/m^3 X3, Input Point #3, Optical Density Y3, Output Point #3, Particulate Mass, mg/m^3 3-14 SEC 3 LIGHTHAWK 560 OPT HD.DOC...
Page 33: Enhanced Remote Panel With Multi I/Omodule
Mother Board. Modules of the Enhanced Remote Panel Mother Board SBC332 Processor Board LonWorks® LTM-10 Board Terminal Block PC Board Power Supply Board Multi I/O Board LCD w / Driver Board SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 34: Electrical Description
They are connected to and driven by the Mother Board via a six pin ribbon cable (J3). 4.3.2.4 Security Key Switch The Security Key Switch is functionally in parallel with the administrator password. Protected variables can be unlocked with the administrator password or Key Switch. SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 35 A simple serial communication interface for monitoring of network variables is provided. The user can use a standard terminal emulator program on a PC to communicate with the panel. Communication is provided on both the RS-232 and SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 36 Enhanced Remote Display responds with: 1 Head Status : 0<CR> Transmission of the characters ‘255?<CR>’ will cause all available variables to be sent sequentially, i.e., starting with variable 1, followed by 2, etc., until the last variable is reached. SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 37 Data Driver Converter Buss Protection Buffer Backlight Driver Control lines to each processor FTT10A DC to DC Network LTM10 Converter -20VDC & Processor Driver Reset -24VDC Figure 4.1 Block Diagram, Mother Board, 1803-020 SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 38 1. J1, J4, J5A, J5B, J6, and J11 on the SBC332 board are actually connectors. NEVER jumper together any of the pins on these headers. 2. Bold print or shading indicates the standard selection. SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 39 JU20 Out = unterminated IN = terminated done elsewhere. NOTES : 1. For exact jumper positions as shipped see “Site Specification Data Sheets” in Appendix A. 2. Bold print indicates the standard selection. SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 40 “Analog Output Isolators” table. If the Multi I/O receives conflicting or overlapping requests for output, its priority handler will assign requests from the Isolator Inputs top priority and the keypad requests from the Enhanced Remote Display second priority. SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 41 TEST FULL SCALE, TEST MID SCALE or TEST ZERO SCALE modes. Data Valid and Fault are fail-safe in nature: they are energized during normal operation and de-energized during instrument failure conditions. SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 42 Ave Mass load Purge Failure Zero on A.O Level #1 Level #1 Level #1 Ave Opacity Ave Opt Density Ave Mass load No Selection Upscale on A.O. Level #2 Level #2 Level #2 4-10 SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 43 Optical Head -5V Analog Power Supply in VDC. (Service Data selection) Supply +5V Digital Power (+/-5%) Optical Head +5V Digital Power Supply in VDC. (Service Data selection) Supply No Selection Deactivates output. SEC 4 LIGHTHAWK 560 ERP VER 2.DOC 4-11...
Page 44 NOTE: Digital input #6 is not used. Digital inputs 1 through 5, 7 and 8 require actuation for 5 seconds before the software will recognize the input as a valid request. This is intended to prevent mode changes due to external transients. 4-12 SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 45: Operational Description
From any one of the six pages of this display press the “↵” key to view the first level “Main” menu. The “ESC” key will bring you back up to this screen. SEC 4 LIGHTHAWK 560 ERP VER 2.DOC 4-13...
Page 46 RAM ICs. If they pass, a message is briefly displayed on the screen before the logo. If either one fails, a message indicating which chip failed remains on the screen and the CPU halts. 4-14 SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 47 ZERO Output Secs. Change Cal Cycle UPSCALE Output Secs. Opacity PLCF Output Secs. Properties Set Points DUST COMP Output Secs. Change Signal Gain Change Part Optics Reference Gain Mass Curve Properties Common Gain SEC 4 LIGHTHAWK 560 ERP VER 2.DOC 4-15...
Page 48: Main Menu Screen
This screen is view only. The information displayed is useful in determining the status of the Optical Head assembly. Use the “ESC” or “↵” key to exit the screen when you are done. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.) NOTE: This screen corresponds to parts of the Service Data Bank of the Optical Head.
Page 49: Change Attenuator Values
For example a “7” in any status word digit would mean that three errors were present, the 1, 2, and 4 errors of that digit. Use the SEC 4 LIGHTHAWK 560 ERP VER 2.DOC 4-17...
Page 50: Output & Cal Tests
“Page Up” or “Page Down” key to move between pages. Press the “↵” to return to the exit screen when you are done. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.)
Page 51: Analog Outputs 1,2
The Relay Assignment menu configures the conditions for closure of the eight output relays. Use the arrow keys to select the menu you want then press “↵”. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.) 4.4.12 Analog Outputs 1,2...
Page 52: Relay Assignments
If one of the fields is not correct, use the “↑” or “↓” key to scroll to it. Once corrected move to SAVE THIS CONFIG. and press the “↵” key. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.) 4.4.15 System Properties Menu...
Page 53: View System Properties
Common) and the calibration cycle parameters (Calibration Time, Cal Interval, Cal Upscale, Zero, PLCF and Dust Comp Output Seconds). It is view only. No changes can be made. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.) 4.4.19 Change Cal Properties...
Page 54: Change Optics Properties
LIGHTHAWK 560 OPACITY/DUST MONITOR 4.4.20 Change Optics Properties This screen is password protected. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.) There are three parameters available on the screen: SIGNAL GAIN, REFERENCE GAIN and COMMON GAIN.
Page 55: Change Password
“↵”, then move to SAVE THIS CONFIG. with the “↑” or “↓” keys and press “↵”. Press “ESC” to exit this screen. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of indivi dual screens.)
Page 56: View Part. Mass Points
Each point consists of an Optical Density value and an associated Particulate Mass value. Press the “ESC” or enter key to exit. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.) 4.4.26 Change Part.
Page 57: Display Properties Menu
To increase display backlight brightness, press “Page Down” and hold the “↑” key. To decrease display backlight brightness, press “Page Down” and hold the “↓” key. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.) 4.4.28 View Alarm Set Points The current alarm set points may be viewed from this screen.
Page 58: View Trending Data
LIGHTHAWK 560 OPACITY/DUST MONITOR can be made from here. Press “ESC” or “↵” to return to the previous screen. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.) 4.4.29 View Trending Data This menu screen selects the parameter trend to be displayed.
Page 59: View Status History
Each entry consists of a code, the date, and time it occurred. Status words can be decoded as per the STATUS CODE HELP screen. (Consult the LightHawk 560 Menu Tree diagram of Section 4.0 to find the menu/submenu location of individual screens.) 4.4.34 View Alarms History...
Page 60 LIGHTHAWK 560 OPACITY/DUST MONITOR (This page intentionally left blank.) 4-28 SEC 4 LIGHTHAWK 560 ERP VER 2.DOC...
Page 61: Purge System Overview
NOTE: One of the primary causes of blower motor failure is the location of the inlet to the Purge System. These systems must draw air that is free from corrosive gaseous pollutants so that the lubricant in the bearings of the motors is not contaminated. SEC 5 LIGHTHAWK 560 PURGE SYS.DOC...
Page 62: Operation
If purge air is halted or reduced for any reason, the purge shutter will begin to close and drop down into the optical path of the monitor. SEC 5 LIGHTHAWK 560 PURGE SYS.DOC...
Page 63: Instrument Air Purge Option
Connection to the Retroreflector and Optical Head Assemblies is via 3/8 inch tube. Reference Model 560 Opacity w/Inst Air System Installation drawing provided. Customer must supply hardware to connect Instrument Air to both Optical Head and Retroreflector Assemblies. SEC 5 LIGHTHAWK 560 PURGE SYS.DOC...
Page 64 LIGHTHAWK 560 OPACITY/DUST MONITOR (This page intentionally left blank.) SEC 5 LIGHTHAWK 560 PURGE SYS.DOC...
Page 65: Calibration Kit Overview
Since the clearances are small on the precision locator pins, it may be necessary to wiggle the test fixture a bit so that the locator pins go into the subassembly face to their full extent before beginning to tighten SEC 6 LIGHTHAWK 560 CAL KIT.DOC...
Page 66: Storage
The Calibration Kit Fixture and attenuators should be stored in the protective case provided when not in use. Store the case in a location that will prevent dirt contamination of the optical surfaces and is not subject to extremes in temperature. SEC 6 LIGHTHAWK 560 CAL KIT.DOC...
Page 67: Maintenance & On-Stack Calibration
5.0 and 6.0 mA, currents of up to 10.0 mA are perfectly normal for your monitor and do not require readjustment. LED currents beyond 10 mA should be investigated and Teledyne Monitor Labs recommends an Off- Stack Calibration described in Section 8.0 of this manual.
Page 68 Purge Shutters are optional equipment and may not be present on every LightHawk 560. The Purge Air Shutters are not included on an upgrade from the LS541, 1100M, or MC2000. If so equipped, check the condition of Purge Shutters by looking through alignment eyepiece window on the Optical Head.
Page 69 Retroreflector. Retroreflector Assembly Retroreflector Assembly alignment is achieved by use of the Integral Retro Alignment Site. The Retro Alignment Site provides a visual indication during SEC 7 LIGHTHAWK 560 ON STACK MAINT.DOC...
Page 70 The Retro Alignment Site is useful for providing on-line feedback during analyzer operation of small changes in Retroreflector position once initial alignment has been performed. It is well suited for alignment indication during normal operation. SEC 7 LIGHTHAWK 560 ON STACK MAINT.DOC...
Page 71: On-Stack Calibration
Appendix B of this manual contains an On-Stack Calibration Checklist to aid the user in performing the calibration. Teledyne Monitor Labs recommends this data be retained to provide a historical record of the opacity monitoring system. 7.2.1 Procedure for On-Stack Calibration Checklist...
Page 72 DISPLAY, first press the enter key ( ) to go to the SYSTEM ↓ PROPERTIES, then use the down arrow ( ) to select VIEW SYSTEM ↵ PROPERTIES and press enter ( ) to select. SEC 7 LIGHTHAWK 560 ON STACK MAINT.DOC...
Page 73 LED current levels. Although typical factory LED currents are between 5.0 and 6.0 mA, currents of up to 10.0 mA are perfectly normal for your monitor and do not require readjustment. LED currents beyond SEC 7 LIGHTHAWK 560 ON STACK MAINT.DOC...
Page 74 • Purge Shutters - Purge Shutters are optional equipment and may not be present on every LightHawk 560. The Purge Air Shutters are not included on an upgrade from the LS541, 1100M, or MC2000. If so equipped, check condition of Purge Shutters by looking through alignment eyepiece window on the Optical Head.
Page 75 “SET” keys on the keypad until the SET LED quits blinking. The “SET” and “NORM” keys must be pressed continuously for about 10 seconds. The YELLOW “SET” LED will flash at a two second rate during this SEC 7 LIGHTHAWK 560 ON STACK MAINT.DOC...
Page 76 Cal Zero section of the Cal Mechanism and the Cal Kit are outside the allowable range. Teledyne Monitor Labs strongly suggests an Off-Stack Calibration as outlined in Section 8.0 of this manual to determine the source of the malfunction and correct this problem.
Page 77 Where the actual value = Labeled %opacity / 100 Remove the Cal Kit Fixture. Close the Optical Head Assembly. Install the weather cover. At this time all stack checks are completed. Return to the Enhanced Remote Display. SEC 7 LIGHTHAWK 560 ON STACK MAINT.DOC 7-11...
Page 78: Attenuator Audit
The Enhanced Remote Panel is capable of recording, storing, and displaying an entire Attenuator Audit: Initial and final Zero, and 15 Attenuator values (5 runs of 3 attenuator values). Contact Teledyne Monitor Labs Tech Support at (800) 846-6062 for Technote #0049.opc.
Page 79: Off-Stack Calibration
Small changes (± 10%) in the flange to flange calibration distance discovered by the user may be compensated for by performing a new clear path zero calibration. The Teledyne Monitor Labs factory should approve changes beyond the + 10% limit. This will insure that the appropriate optical elements are installed before the recalibration begins.
Page 80: Generating An Optical Clear Path Opacity Signal
Teledyne Monitor Labs in the Site Specification Data Sheets of this manual. If test stands are not available, a table whose length is greater than the “flange to flange”...
Page 81: Actual Clear Path Conditions
Alignment is achieved by adjusting the head so that the cross hairs are centered on the bright green image of the Retroreflector and the eyepiece circles are concentric with the image. SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 82: Retroreflector Assembly
Cap and observing the green light projected from the Optical Head. 2. Adjust the 4 nuts on the mounting bolts until the bore of the Retro and purge nozzle is nominally centered on the projected beam. SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 83: Cleaning The Optical Surfaces
The external optical windows and surfaces should be cleaned using a clean soft lint free cloth (Kimwipe® or equivalent) and quality commercial glass cleaning solution. Both are available from Teledyne Monitor Labs. An ammonia based window cleaner may be used so long as it does not contain any anti-fog additive.
Page 84: Cleaning Procedures
50% alcohol and 50% distilled water. Care should be taken not to use alcohol containing oily contaminates as this will leave a residue on the optical surfaces. Teledyne Monitor Labs recommends the use of a reagent grade isopropyl alcohol. Many optical surfaces are treated with an anti-reflective coating.
Page 85: Optical Head Zero And One Hundred Percent Opacity
4. Depress the “←” key again. The 4 digit display will still display all 0’s, but the 2 LSD will now be blinking. 5. Depress the “↑” key until the 2 LSD is a 6. SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 86 To adjust the LED current the Reference Gain must be changed. To increase the current, decrease the Reference Gain. To decrease the current, increase the Reference Gain 1. Manipulate the keypad until the Reference Gain (location F9) is displayed. 0 0 1 5 SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 87: Setting The Signal Gain
LED current is between 5.0 and 6.0 mA. 5. If the required Reference Gain is greater than 125, this may be an indication of potential LED problems. Contact Teledyne Monitor Labs Tech Support at (800) 846-6062 before proceeding.
Page 88: Final Calibration Set Function Routines
Routines. 8.5.3 Final Calibration SET Function Routines NOTE: Performing the “SET” functions will configure the LightHawk 560 firmware to accurately output the ZERO, 100% and linear intermediate opacity values. Although these routines are simple, they must be followed carefully and be performed in the following order.
Page 89 Iris of the Cal Mechanism must be adjusted as described in steps (a) through (h) below. NOTE: If theU1 reading is less than + 2 % go to step 10. a) Loosen the Allen head setscrew that locks the Zero Iris in place. See Figure 8-4. SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC 8-11...
Page 90 Iris carefully so that the normal variation is equally balanced around the 0% reading. d) Carefully lock down the Iris setscrew. See Figure 8-4. e) Allow the monitor to operate in the Zero mode for an additional 2 minutes. 8-12 SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 91 Cal Mechanism. Go to the UPSCALE mode by pressing the “UPSCALE” key on the keypad. Manipulate the keypad to display the Instantaneous Opacity (location U0). Allow the instrument to remain in the SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC 8-13...
Page 92 “UPSCALE” keys on the keypad. When the Cal Cycle is complete, check that the last Zero Calibration (location U6) is the same value as Dust Compensation (location U8). If they are not, recheck all the SET functions. 8-14 SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 93: Adjusting Calibration Kit
5. To unlock the Iris, loosen the small clamp screw located at the six o’clock position on the round backing plate just behind the larger gear. This will allow the gear to rotate and open and close the Iris. SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC 8-15...
Page 94 Cal Kit Iris. See Section 8.9 for the Cal Kit Neutral Density Window Replacement procedure. 9. Carefully loosen the gear clamp and remove the cover. Reinstall the cover and tighten the cover retaining screws. 8-16 SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 95: Verify The Response Of The Optical Head
Cal Mechanism. See Appendix C for ND window part numbers. The Cal Mechanism Iris opening diameters must be between 3/16 inch and 7/16 inch. If during Iris adjustments these limits cannot be maintained, the ND window must be changed. SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC 8-17...
Page 96 7. The Iris can now be readjusted so the opening diameter is within specification. If the Zero Iris ND window was replaced, return to Section 8.5.3, Step 5. If the Upscale Iris ND window was replaced, return to Section 8.5.3, Step 16. 8-18 SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 97: Cal Kit Neutral Density Window Replacement
Optical Density value. If the Iris opening is too large, the ND Window must be replaced with one of a lower Optical Density value. 1. Loosen the cap screws and remove the cover that protects the Iris Adjustment Mechanism. See Figure 8-8. SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC 8-19...
Page 98 8. The Cal Kit Iris can now be readjusted so the opening diameter is within specification. Return to Section 8.6. Allen Screws Gear Gear Screw ND Cover Front Gasket ND Window, coating toward Rear Gasket Rear Gasket Protective Cap Collar Figure 8-8 8-20 SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 99: Off-Stack Calibration History
The precise distance between the opposing faces of the mounting flanges for the monitor The precise distance between the Optical Exit Window and the Retroreflector Surface Window Parameter location F9 Parameter location F8 Parameter location C1 Table 8-1 SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC 8-21...
Page 100 LIGHTHAWK 560 OPACITY/DUST MONITOR (This page intentionally left blank.) 8-22 SEC 8 LIGHTHAWK 560 OFF-STACK CAL.DOC...
Page 101: Installation
SECTION 9.0, INSTALLATION 9.0 INSTALLATION The installation overview of the LightHawk 560 system is shown in the Installation Drawing. It is important that the optical center line of the Optical Head and Retro be maintained so that they are capable of being pointed directly at each other.
Page 102 For a mounting to be 2 feet or 24" long, the maximum angle would fall to 1.15°. To avoid very small misalignment angles the mounting tube diameter should be increased when long mounting tube lengths (L) are required. 1" LIGHT BEAM 560 Opacity Port Alignment FIGURE 9-1 SEC 9 LIGHTHAWK 560 INSTALL.DOC...
Page 103: Distance Determination
SECTION 9.0, INSTALLATION Teledyne Monitor Labs has a mounting plate alignment scope, which may be used to aid the user in determining the optical centerline between the two opposing ports. CAUTION: The pipes must not be rigidly connected to the inner and outer shell stacks since they may move differently.
Page 104: Power Requirements
Failure to provide purge air to the system components could result in damage to the system that will not be covered under the Teledyne Monitor Labs warranty. Power to the Purge System should be provided via a circuit that is always activated so long as the stack is in operation.
Page 105: Enhanced Remote Display Assembly
9.8 ENHANCED REMOTE DISPLAY ASSEMBLY The Enhanced Remote Display Assembly may be 19" (483mm) rack mounted, panel mounted, or located inside an enclosure. See Section 1.2 Specifications for ambient temperature conditions of the Lighthawk 560. SEC 9 LIGHTHAWK 560 INSTALL.DOC...
Page 106 LIGHTHAWK 560 OPACITY/DUST MONITOR (This page intentionally left blank.) SEC 9 LIGHTHAWK 560 INSTALL.DOC...
Page 107: Troubleshooting
XXX2 Purge Fail Retro Side: Check the blower operation, blower plumbing and Retro side pressure switch. XXX4 Out of Service: The LightHawk 560 has been logged out of service. Check the value of F6. For normal operation F6 must be set to 0.
Page 108: Extended Status Code U4
1XXX Not Used 2XXX Not Used 4XXX Not Used 10.3 ASSISTANCE If you are unable to determine the problem, call Teledyne Monitor Labs Tech Support at (800) 846-6062. An experienced factory trained technician will handle your call. 10-2 SEC 10 LIGHTHAWK 560 TROUBLESHOOTING.DOC...
Page 109: Site Specification Data Sheets
APPENDIX A SITE SPECIFICATION DATA SHEETS...
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Page 111: Maintenance Check Sheets
APPENDIX B MAINTENANCE CHECK SHEETS...
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Page 113 APPENDIX B, MAINTENANCE CHECK SHEETS Rev. 3/16/06 PAGE 1 OF 3 TELEDYNE MONITOR LABS ON-STACK CALIBRATION CHECKLIST for LightHawk 560 OPACITY SYSTEM PLANT NAME LOCATION SERVICE PERSON SERIAL # DATE A. REASON FOR CALIBRATION QUARTERLY EMERGENCY INSTALL OTHER EXPLAIN: Enhanced Remote Display Checks A.
Page 114 A. LED CURRENT (S2) B. INSPECT PURGE FLEX MOUNTING PURGE DESIC- FILTERS HOSES TUBES SHUTTERS CATOR CLEANED REPLACED Optical Head Retro OPTICAL ALIGNMENT Alignment as found Alignment as found HEAD RETRO ADJUSTED COMMENTS: APP B LIGHTHAWK 560 MAINT CHK SHTS.DOC...
Page 115 ATTENUATOR VALUE CORRECTED VALUE LightHawk READING OUTPUT VALUE (DAS) DIFFERENCE (+/- 2.0 %) DATA COLLECTION A. RE-CHECK OUTPUT DEVICE VALUES ABOVE "AS LEFT" FILL IN OPACITY READINGS SECTION 2A NOTES OR RECOMMENDATIONS : APP B LIGHTHAWK 560 MAINT CHK SHTS.DOC...
Page 116 LIGHTHAWK 560 OPACITY/DUST MONITOR (This page intentionally left blank.) APP B LIGHTHAWK 560 MAINT CHK SHTS.DOC...
Page 117: Spare Parts
APPENDIX C SPARE PARTS...
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Page 119 APPENDIX C, RECOMMENDED SPARE PARTS RECOMMENDED SPARE PARTS Recommended spare parts for the LightHawk 560 are organized into four categories. User can stock the appropriate parts for their level of maintenance. The four lists do not overlap. For the highest level of maintenance the first three lists should be stocked. The “Recalibration” list is for reference only in the event that major path length or optical changes are necessary.
Page 120 The following table represents a selection of parts and supplies that may be required during start up and normal operation. This is the least comprehensive list. These parts will support only a minimal maintenance level. TELEDYNE MONITOR LABS (TML) LIGHTHAWK 560 “START UP/OPERATIONAL” RECOMMENDED SPARE PARTS Stocking...
Page 121 APPENDIX C, RECOMMENDED SPARE PARTS “Normal Wear and Maintenance” Spare Parts These are parts that may be used as a result of normal wear over time. TELEDYNE MONITOR LABS (TML) LIGHTHAWK 560 "MAINTENANCE" RECOMMENDED SPARE PARTS Stocking Stocking Stocking Cal Kit...
Page 122 The following is a list of spares that the user may wish to keep on hand in order to minimize system downtime in the event of an unforeseen failure such as power surges, lightning strikes, etc. TELEDYNE MONITOR LABS (TML) LIGHTHAWK 560 "EMERGENCY/QUICK RESPONSE" RECOMMENDED SPARE PARTS Stocking...
Page 123 The following is a list of neutral density windows used in the Calibration Mechanism and Calibration Kit. These windows only need changed if directed by the Off-Stack Calibration procedure outlined in Section 8.0 of this manual. TELEDYNE MONITOR LABS (TML) LIGHTHAWK 560 “RECALIBRATION” PART NOS. Stocking...
Page 124 LIGHTHAWK 560 OPACITY/DUST MONITOR (This page intentionally left blank.) APP C LIGHTHAWK 560 SPARE PARTS.DOC...
Page 125 APPENDIX D DRAWINGS...
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Page 153 APPENDIX E ENHANCED SERIAL PORT COMMUNICATION PROTOCOL...
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Page 155 One function is a more robust and error free way in which to request data. The other function has the ability to command and control calibrations and initiate other modes of operation. It is important to note that program parameters CANNOT be modified from the serial ports. APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...
Page 156 The “variable number” is the same number designation used to number the variables in the original protocol. A list of the variable numbe rs can be obtained from the Enhanced Remote Panel by using the original 255? command. An example is included later in this appendix. APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...
Page 157 If the following command line is given to the ENHANCED REMOTE PANEL, it will list the commands available for the calibration input command line such as shown in the above table. 997 ? <CR><LF> APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...
Page 158 Proper usage is: 997?<cr> This variable is used to request a calibration mode for the Optical Head from the serial port. Proper usage is as follows: 998,"DESIRED MODE",998,"DESIRED MODE"<cr> This variable is not used APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...
Page 159 VAR 6: 0 VAR 7: 0 VAR 7: 0 VAR 8: 0 VAR 8: 0 TIME SEC: 0 TIME MIN: 0 NO SELECTION TIME = NO BROADCAST ? + TO ENTER, ESC TO CANCEL APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...
Page 160 Note that RS-422 communication is also at 9600 baud and it requires using 2 stop bits. ENHANCED REMOTE MOTHERBOARD JUMPERS for Serial Communication Jumper Options RS-232 RS-422 RS-485 UART TPU UART UART UART UART TPU UART UART UART UART TPU 422 UART UART APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...
Page 161 24 CAL ZERO SET VOLTAGE:6.39 25 BACKGROUND SET Volts:0.10 26 Optical Head Temp:27.30 27 Calib Mech Posit:168 28 +15V Supply Voltage:14.92 29 -15V Supply Voltage:-14.96 30 +5V Analog Supply:5.00 31 -5V Analog Supply:-5.05 32 +5V Digital Supply:4.95 APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...
Page 162 69 Dig Out 2:UPSCALE ON AO 70 Dig Out 3:ZERO ON AO 71 Dig Out 4:INST OPAC LEVEL1 72 Dig Out 5:AVG OPAC LEVEL1 73 Dig Out 6:PURGE FAILURE 74 Dig Out 7:DATA VALID 75 Dig Out 8:FAULT APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...
Page 163 108 Averaging Interval:6 109 Opac Alarm State:1 110 OptD Alarm State:1 111 Part Mass Alrm state:1 112 Cal Mechanism Mode:NORMAL MODE 113 Six PIO Mode:NORMAL MODE 114 Audit Mode:NOT IN AUDIT 115 Filter Value:NO FILTER APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...
Page 164 143 Mid TargetValue:0.00 144 High TargetValue:0.00 145 Low ArithMean:0.000 146 Mid ArithMean:0.000 147 High ArithMean:0.000 148 Low ConCoeff:0.000 149 Mid ConCoeff:0.000 150 High ConCoeff:0.000 151 Low CalError:0.00 152 Mid CalError:0.00 153 High CalError:0.00 E-10 APP E LIGHTHAWK 560 SERIAL PORT PROTOCOL.DOC...

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