LUDLUM 4525-14000 Generation 5 Radiation Portal Monitors Installation Guide
- June 1, 2024
- LUDLUM
Table of Contents
LUDLUM 4525-14000 Generation 5 Radiation Portal Monitors
Specifications
- Models: 4525-7000, 4525-10500, 4525-14000
- Generation: 5
- Installation Manual: February 2024
Product Usage Instructions
- Section 1 – Packaging
- Ensure that all components specified for each model (4525-7000, 4525-10500, 4525-14000) are present and undamaged upon receipt.
- Section 2 – Installation
System Buffer Zone
Allocate a buffer zone for the system to ensure proper functioning and
access for maintenance.
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: 1-800-622-0828 (US, CA)
- Fax: 325-235-4672
- 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
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.
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).
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).
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
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.
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.
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.
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.
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.
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.
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
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.
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 rsdtech@ludlums.com 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.
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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