DynAmp LKAT2 Installation, Operation And Service Instructions

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DynAmp

LKAT

+24V

BI.DIRECTIONAL HIGH CURRENT

MEASUREMENT SYSTEM with RECTIFIER

PROTECTION FUNCTION

lnstallation, Operation and Service Manual

Manual ltem No. 046404

Rev. E

DynAmp, LLC

Installation, Operation and Service Manual LKAT2 +24V

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Installation, Operation and Service Manual LKAT2 +24V

DynAmp, LLC WARRANTY

Items and components manufactured by DynAmp, LLC for permanent installation are warranted to be free from defects in material and workmanship for a period of two (2) years from the date of shipment.

Items and components manufactured by DynAmp, LLC for portable and temporary use in more than one location are warranted to be free from defects in material and workmanship for a period of eighteen (18) months from the date of shipment.

Items and components not manufactured and resold by DynAmp, LLC are warranted by their manufacturer.

Warranty repair shall be, at DynAmp’s option, in the form of repair or replacement of the defective items or components. Concerning warranty repairs, DynAmp, LLC will be responsible for DynAmp provided time, material and transportation costs (shipping or travel). Actual method of warranty repair / correction will be determined by DynAmp, LLC at DynAmp’s sole option. Such warranty repair shall constitute a fulfillment of all DynAmp, LLC liabilities in respect to said items and components. In no event shall DynAmp, LLC be liable for consequential damages.

Information in this document is subject to change without notice. © 2014, 2016, 2017, 2018 DynAmp, LLC. All rights reserved. Reproduction in any manner whatsoever for purposes other than installation, operation, or

service by the purchaser or end user without the written permission of DynAmp, LLC is strictly forbidden.

This manual is part of the complete set of product documentation that includes installation, operation, and service instructions, drawings and test results. Users should evaluate the information in the context of the complete set of product documentation and their particular applications. DynAmp, LLC assumes no liability for any incidental, indirect, or consequential damages arising from the use of this documentation.

While all information presented is believed to be reliable and in accordance with accepted engineering practices, DynAmp, LLC makes no warranties as to the completeness of the information.

All trademarks used in association with LKAT

are trademarks of DynAmp, LLC.

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Installation, Operation and Service Manual LKAT2 +24V

GENERAL

VOLTAGE

INSTALLATION

Hazard Warning!

HAZARDOUS

All installation, maintenance and service must be performed by qualified technicians who are familiar with the warnings and instructions of this manual.

Use of the equipment in a manner not specified by the manuf acturer can impair the protection provided within.

The enclosure cover must remain closed at all times during operation to ensure safety of personnel. The cover may be opened using a screwdriver; however, only authorized personnel or technicians should be allowed to open and service the unit.

DynAmp, LLC does not assume liability for the customer’s failure t o comply with the rules and requirements provided in this manual.

This equipment is designed to be connected to hazardous electric voltages. Ignoring the installation precautions and warnings can result in severe p ersonal injury or equipment damage.

To avoid the risk of electrical shock or fire, the safety instructions and guidelines in this manual must be followed. The electrical specifications must not be exceeded and the unit must be installed according to directions provided.

This equipment is intended for indoor or outdoor use. It should be mounted in a well-ventilated area, away from high heat, dust, and corrosive atmosphere. The ambient temperature must not exceed specified limits.

For mounting considerations that fall outside the recommended specifications provided in this manual, the factory should be contacted for approval.

This unit is rated for installation category II and pollution degree 2.

Symbol Identification:

General definitions of safety symbols used on equipment and manual.

Caution/Warning: Refer to accompanying documents for instructions.

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SAFETY

The Measuring Head is designed to be installed on high voltage bus bars. All interconnection cables must be safely routed away from bus bars and high voltages. Do not allow any interconnection cable to contact bus bars or high voltages.

Ignoring the installation precautions and warnings can result in severe personal injury or equipment damage. The following are general guidelines to be followed during installation, operation and service of the Metering Unit and Measuring Head.

• All installation, maintenance and service must be performed by qualified technicians who

are familiar with the warnings and instructions of this manual.

• Always follow all local and plant safety procedures.

• The enclosure cover must remain closed at all times during operation to ensure safety of

personnel. Only authorized personnel or technicians should be allowed to open and service the unit.

• Units are not intrinsically safe. Do not place in explosive atmospheres.

• Service must be performed by qualified technicians only. If use of an oscilloscope

becomes necessary during servicing, the scope must be floating and ungrounded or differential probe(s) must be used. The Metering Unit is isolated from the mains via the power transformers. If a grounded scope is used, a hazardous condition is created since current will flow through the probe to ground.

• Use of the equipment in a manner not specified by the manufacturer can impair the

protection provided within.

• If a binding screw is used for the mains earth connection, the binding screw must be size

M4 (No. 6) or larger.

DynAmp, LLC does not assume liability for the customer’s failure to comply with the rules and requirements provided in this manual.

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DynAmp, LLC Customer Support & Service Assistance

For further assistance, contact DynAmp Customer Support at:

Americas: Telephone: +1 614.871.6900 Fax: +1 614.871.6910 8:00 AM to 5:00 PM USA Eastern Time From first Sunday in November to second Sunday in March – 13:00 GMT to 22:00 GMT From second Sunday in March to first Sunday in November – 12:00 GMT to 21:00 GMT

After Hours Critical Service Emergency: Telephone: +1 614.871.6906 5:00 PM to 8:00 AM USA Eastern Time From first Sunday in November to second Sunday in March – 22:00 GMT to 13:00 GMT From second Sunday in March to first Sunday in November – 21:00 GMT to 12:00 GMT

Central e-mail: help@dynamp.com

DynAmp web: www.dynamp.com

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Page

Change

Reason For Revision

Date

all

Rev NEW

06/14

all

CAR 10190 – Refine manual

08/14

17,18

ECR 2029 – Detail added to Form 1 & 2 showing pin numbers

09/16

vi, v, 9,10,

30,31

ECR 2177 – Update drawing 75A109415 Rev A to B

10/17

5, 27,

ECO #3346 - Update MUT description, Non-Failsafe and

07/18

25, 31

ECR #2225 – Regroup terms of equation 5 .2 for clarification, remove drawing 75A109415B

09/18

MANUAL REVISIONS

14, 29,

ECO 3337 – Delete fuse references, input power voltage, Meter Unit item number, drawing list

drawings

01/17

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TABLE OF CONTENTS

Paragraph Title Page

DynAmp, LLC WARRANTY ________________________________________________ iii Hazard Warning! _________________________________________________________ v SAFETY _______________________________________________________________ vii DynAmp, LLC Customer Support & Service Assistance ________________________ ix MANUAL REVISIONS _____________________________________________________ xi TABLE OF CONTENTS ___________________________________________________ xiii

1. HANDLING AND STORAGE______________________________________________________ 1

2. PRODUCT DESCRIPTION _______________________________________________________ 3

2.1 SYSTEM OVERVIEW ............................................................................................................. 3

2.2 ADDITIONAL MEASURING HEA D DETA IL ............................................................................ 6

2.3 ADDITIONAL METERING UNIT DETAIL ................................................................................. 6

2.4 ADDITIONAL INDI CAT OR AND OUTPUT DETAIL ................................................................. 7

2.5 INTERCONNECTIO N CABLE DETAIL .................................................................................... 7

3. SPECIFICATIONS ______________________________________________________________ 9

4. INSTALLATION _______________________________________________________________ 13

4.1 HANDLING PRECAUTIO NS ................................................................................................. 13

4.2 INSTALLATIO N CONSIDERATIONS .................................................................................... 13

4.3 OFF-BUS FUNCTIONAL CHECK (Optional) ......................................................................... 14

4.4 MEASURING HEAD INSTALLATION .................................................................................... 14

4.5 METERING UNIT INSTALLATION ........................................................................................ 15

4.6 SYSTEM CHECKOUT ........................................................................................................... 16

5. THEORY OF OPE RATION ______________________________________________________ 19

5.1 GENERAL ............................................................................................................................. 19

5.2 OLOP TECHNOLO GY .......................................................................................................... 19

5.3 SYSTEM FUNCTIONAL DESCRIPTION ............................................................................... 20

5.4 LKAT

5.5 LKAT

METERING UNIT ....................................................................................................... 21

MEASURING HEAD INTERCHANGEABILITY ........................................................... 21

5.6 TROUBLESHOOTING AN ACCURACY DIAGNOSTICS FAULT INDICATION ..................... 21

5.7 SYSTEM CALIBRATION OVERVIEW ................................................................................... 22

5.8 CALIBRATION ADJUSTMENTS ........................................................................................... 23

5.9 FIELD CONFIGURATION OF TRIP SETPOINTS ................................................................. 25

5.10 EARTH GROUNDING ........................................................................................................... 26

5.11 CONFIGURING THE LOW PASS FILTER ........................................................................... 26

5.12 “FAILSAFE” / “NON-FAILSAFE” CONFIGURATION ............................................................ 27

6. MAINTENANCE & SPARE PARTS _______________________________________________ 29

6.1 PERIODIC MAINTE NANCE .................................................................................................. 29

6.2 ANNUAL MAINTENANCE ..................................................................................................... 29

6.3 SPARE PARTS ..................................................................................................................... 30

7. DRAWINGS __________________________________________________________________ 31

Installation, Operation and Service Manual LKAT2 +24V

FIGURES, FORMS & TABLES

Figure # Title ........................................................................................................................... Page

Figure 3.1 LKAT2 Frequency Response ................................................................................... 11

Form 1 LKAT Form 2 LKAT Figure 5.1 Block Diagram of the LKAT

Diagnostic Measurements Form – Zero Primary Current ................................... 17

Diagnostic Measurements Form – Energized Primary Bus ................................ 18

System........................................................................ 20

Table 2.1 Main and PE PC Board Assembly Features.............................................................. 7

Table 3.1 LKAT

Table 5.1 Troubleshooting an Accuracy Diagnostics Fault Indication ....................................... 22

Table 5.2 Trip Configuration Details ......................................................................................... 25

Table 5.3 Low Pass Filter Switch Settings ................................................................................ 26

Table 5.4 LKAT

Table 6.1 Spare Parts List ........................................................................................................ 30

Table 7.1 Drawing List .............................................................................................................. 31

System Specifications ( subject to change without notice )............................ 9

Alarm Relay Status ........................................................................................ 27

Installation, Operation and Service Manual LKAT2 +24V

1. HANDLING AND STORAGE

DynAmp products are engineered and manufactured for use in industrial environments. However, t hey contain sensitive electronic and mechanical components which may be damaged and fail if not handled and stored properly. All products must be handled and stored with the same care as any precision measurement instrument. Severe bumps or jolts may damage internal parts and cause malfunction or premature failure. DynAmp products are designed and assembled with conformal coating, shock mounting, and environmental seals, when appropriate or when specified. However, this protection requires that the product must be properly installed and operational before the protection is fully functional. Therefore, adequate protection from humidity, shock, and temperature must be provided during handling and storage prior to installation.

The handling and storage of equipment must be sufficient to meet the storage temperature and humidity specifications of the product and to prevent any condensation or contact with water or any other liquid. The storage location and container or crate must provide adequate protection from precipitation (rain, snow, ice) and direct water contact. Adequate shelter must be provided to prevent the accumulation of precipitation (rain, snow, ice) and water which can lead to the deterioration or failure of shipping containers or crates and cause water ingress. Storage in coastal or industrial areas subject to salt-laden or corrosive air or areas of winddriven sand or other abrasive dust must be adequate to prevent the deterioration or failure of shipping containers or crates and cause ingress. Frequent inspection of storage areas and storage containers or crates is required to ensure proper storage conditions are being maintained.

If the shipping container or crate is opened and/or the equipment is removed for inspection prior to installation, the equipment must be repackaged in the original undamaged container or crate in the same manner as it was shipped to prevent environmental damage or placed in a storage location that meets the required environmental and storage conditions.

General product storage temperature and humidity requirements:

Storage Temperature: -40°C to 70°C

-40°F to 158°F Storage Humidity: Maximum 85%, non-condensing

DynAmp, LLC does not assume liability for the customer’s failure to comply with handling and storage requirements.

For further assistance, contact DynAmp customer support.

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LKAT2 Measuring Head

2. PRODUCT DESCRIPTION

2.1 SYSTEM OVERVIEW

The LKAT2 combines accurate high current measurement with reverse and overcurrent protection in a single rugged and cost effective system.

The next generation of DynAmp’s well proven OLOP of accuracy and stability to accurately and reliably measure uni- and bi-directional DC as well as AC bus currents.

The LKAT

is particularly well suited to measure power rectifier outputs for control and protection purposes in electro-chemical processes such aluminum, chlorine, copper, manganese, titanium, zinc, electroplating, etc.

technology, LKAT2 offers a new level

LKAT

Metering Unit

KEY STANDARD FEATURES

True bi-directional performance. Ideal for difficult magnetic applications. No head position or bus analysis needed.

Extremely compact with excellent environmental specifications for installation flexibility, inside or outside.

Multiple, standard switch selectable measurement output signals including mA, mV and V. Standard Accuracy Diagnostics “AD” continuously monitors system performance providing

both local LED and relay contact output.

Optional LKAT

Protection Extensions, (PE),

provides additional functionality for protecting high current rectifiers. Standard Alarm provides reverse or over-current protection via an LED viewable at the

metering electronics and a dry contact relay output. The LKAT

Metering Unit consists of a +24V power supply and Main pc board mounted together on a steel U-chassis. Input, output, and power connections are made via pc board edge connector plugs.

Installation, Operation and Service Manual LKAT2 +24V

Each standard LKAT

is delivered with the following

• A new, ruggedized two-piece Measuring Head with integrated mounting hardware and bus bar corner (fiberglass angles). Each head half has its own cable for connection to the metering electronics.

• Very compact Metering Electronics with one analog measurement output, one Accuracy Diagnostics system status output and one configurable Alarm output for overcurrent or reverse current protection.

• System output cable

• Power input cable

• Comprehensive User’s Manual

• Factory calibration data and graphs

• 2-year warranty for permanent installed systems

• Packaging suitable for air /ground transport

AVAILABLE OPTIONS

• Protection Extensions ( PE ) The PE option adds additional functionality for protecting high current rectifiers. This option is

either factory configured with a new system or can be added to LKAT field. If added in the field, some field configuration may be required.

Second Freely Scalable Analog Output : This second analog output is independently scaled and fully isolated from the standard LKAT

measurement output. In typical applications, it is scaled to provide accurate measurement above the standard rectifier operating range for advanced protection purposes. For example, the primary LKAT

output may be scaled to 50kA to provide the highest degree of accuracy and resolution for normal rectifier control. The second PE output may be scaled to 75kA to provide the information to intelligently manage overcurrent situations. Using this signal, the rectifier control system could integrate overcurrent operation to allow 5 minutes at 110%, 1 minute at 120%, 10 sec at 140%.

Two Additional Protection Relays : These relays bring total number of configurable relays to three. Each can be configured to

provide reverse or various degrees of overcurrent protection. Like the standard alarm, these two additional PE alarms come with their own, independent local LED indication and relay outputs.

• Digital current display ( 3 1/2 digit ) This option is mounted behind the clear front door of the metering electronics enclosure to

display either DC or RMS AC bus current locally. maximum metering electronics ambient temperature to 50ºC. This option can also be added to LKAT

Systems already in the field.

Please note that this option reduces the

• Custom Cable Lengths Custom Measuring Head cable lengths can be provided but only at time of order. Note that

Measuring Head cable lengths cannot be changed after order or in the field because one end is terminated inside the Measuring Head and the other end is terminated inside a fixed connector.

Custom Signal and Mains cable lengths can be provided. Note that standard Signal and Mains cables can be shortened or replaced with longer cables in the field.

Systems already in the

Installation, Operation and Service Manual LKAT2 +24V

AVAILABLE ACCESSORIES

• Summing / Totalizing multiple LKAT systems A dedicated external module is available for totalizing/ summing LKAT measurement signals.

This is typically used to provide a true ‘total’ current signal when multiple rectifiers ( with individual LKAT systems ) are connected in parallel to provide a higher total current.

• LKAT Metering Unit Tester ( LKAT MUT ) The LKAT MUT is a portable tester used to verify the functionality of Metering Units for all

versions of the LKAT family of products. Adapters included with the LKAT MUT allow the tester to be connected directly and check any

LKAT Metering Unit electronics. The functions and parameters checked by the LKAT MUT include:

• Input / output sensitivity

• Trip point scaling

• Trip relay contacts

• Integrity of input / output harnesses and interconnections on Metering Unit

The tools / documentation required to use the LKAT Metering Unit Tester include :

• 4-1/2 digit DMM with 0.05% basic DC accuracy ( user provided )

• DMM Test probes ( user provided )

• Banana to banana cables ( 1black / 1 red )

• LKAT MUT Product Manual

More information on the LKAT MUT can be found at www.dynamp.com

or by contacting

DynAmp.

Installation, Operation and Service Manual LKAT2 +24V

• Extended Warranty For permanently installed systems, the standard 2-year warranty can be extended in 2-year

increments. This must be ordered less than 6 months after the original LKAT system is shipped.

2.2 ADDITIONAL MEASURING HEAD DETAIL

LKAT2 Measuring Heads contain an arrangement of Hall Effect sensor ICs and signal conditioning electronics. The tubular enclosure is constructed of flame retardant plastic with an internal aluminum frame. Insulation from the bus is provided by the homogeneous (sealed) construction of the head. In the event that the head enclosure components become cracked, the bonding fails, or the weather-tight seal is broken in any way, a replacement head must be substituted. The Measuring Head is not designed to be repaired.

LKAT the corners of the bus bar and stainless steel bus bar mounting screws threaded into the Measuring Head structure. Mounting hardware is supplied with each system. These screws are adjusted to bus dimensions specified with each order. When properly installed, the mounting hardware maintains the position of the Measuring Head in the event of temperature fluctuation and / or bus vibration.

An interconnection cable assembly is integral to each half of the Measuring Head. Measuring Heads with extra-long interconnection cables are also available - consult the factory for details. Standard Measuring Head cable assemblies are terminated with keyed connectors to ensure correct hookup. The interconnection cables from the Measuring Head are identified as “A” and “B”. Connecting head cable “A” to Metering Unit “B” will not result in damage to the head or electronics, but may degrade the calibration accuracy of the system.

Measuring Heads are mounted on the bus bar using fiberglass angles positioned on

2.3 ADDITIONAL METERING UNIT DETAIL

The Metering Unit electronics are housed in an environmentally rugged enclosure. The enclosure cover must remain closed during normal operation.

The outside of the Metering Unit enclosure includes four receptacles for external connection to the Measuring Head, the Metering Unit measurement signal(s) and relay outputs, and the input of mains power. When properly mated with the associated cable assembly, these connections are also environmentally protected.

Internally, all LKAT board. These 2 PC boards are mounted to a steel chassis which is then mounted on a steel panel housed in the enclosure. The Metering Unit enclosure door has a window made of clear polycarbonate. This allows the user to view various LED (or LCD) status indicators while the door is closed. For more information, refer to the “Theory of Operation” section of this manual.

There are two optional pc board assemblies that may be added onto the Main pc board in the

LKAT

Metering Unit:

• The Protection Extensions ( PE ) pc board assembly

• The Display pc board assembly.

One or both of these pc board assemblies may be added to an LKAT field. It is not mandatory that they be factory installed and/or calibrated. The optional pc board assemblies may be calibrated on site, using the LKAT measurement.

Metering Units include both a Power Supply pc board and a Main pc

Metering Unit in the

Main Output as the reference

Installation, Operation and Service Manual LKAT2 +24V

Main PC Board Assembly

with PE PC Board

Assembly

Isolated Output

+1 for 2 total

Operational Status LEDs & Relay Contacts

+0 for 1 total

Overcurrent / Reverse Trip Status LEDs & Relay Contacts

2.4 ADDITIONAL INDICATOR AND OUTPUT DETAIL

As noted on the specifications page, The LKAT2 System Metering Unit includes several visual indicators. These include:

• Accuracy Diagnostics (operational status) LEDs: green = OK, red = system problem (see

Section - “Theory of Operation”).

• Over / Reverse Current Trip status LEDs: green = measured current does not exceed the

setpoint, red = measured current exceeds the setpoint.

• (Optional) Illuminated LCD digital display of measured current.

Available via the Metering Unit output cable:

• Isolated signal output proportional to bus current being measured. This output may be

configured for various zero and full-scale values.

• Normally open and normally closed relay contacts indicate (AD) Accuracy Diagnostics

operational status (same as green and red LEDs).

• Normally open and normally closed relay contacts indicate over / reverse current trip

status (same as green and red LEDs). For failsafe operation, the relay coil is energized in the normal condition (no over / reverse trip).

The table below lists the features associated with the Main and PE pc board assemblies.

Table 2.1

Main and PE PC Board Assembly Features

1 +2 for 3 total

Checking field calibration of LKAT with calibration accuracy of 0.1% full-scale or better. Contact DynAmp, LLC for calibration of the LKAT

System. Refer to “Maintenance and Spare Parts” section for more information.

Systems requires use of a reference current transducer

2.5 INTERCONNE CTION CABLE DETAIL

The LKAT2 System is supplied with two cable assemblies in addition to those connected to the Measuring Head.

The power input cable assembly. A keyed circular connector terminates one end for connection to the Metering Electronics. The other end is unterminated for connection to the power source by the user during installation.

The system output cable assembly. A keyed circular connector terminates one end for connection to the Metering Electronics. The other end is unterminated for connection to the power source by the user during installation. The system output cable is a 17-conductor type. However, only 8 of the 17 conductors are used when the optional PE pc board assembly is NOT installed. The unused conductors may be trimmed flush to cable jacket. The user connects this cable from the Metering Unit to the appropriate inputs during installation.

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MAIN ANALOG SIGNAL OUTPUT

Signal Output Type (configurable)

Zero kA ± Full-scale kA

2V -6V to +10V

Signal Output Calibration Accuracy *

±0.25% full-scale

Repeatability Error Limits *

±0.1% of full-scale

(refer to Figure 3.1 for additional info.)

Temperature Sensitivity

±50ppm/°C or better

Accuracy Diagnostics

Indicates LKAT2 System proper operation or operational problem

Accuracy Diagnostics Status LEDs

Green LED indicates proper operation Red LED indicates operational problem

Accuracy Diagnostics Status Relay Function

Relay coil de-energizes when operational

Over / Reverse Current Trip Setpoint Qty. (1)

Factory/field configurable to trip on either

Setpoint accuracy ±2%

Over / Reverse Current Status LEDs

Green indicates operation OK – No Trip Setpoint

Over / Reverse Current Status Relay

Relay coil de-energizes when measured

All Relay Function

Form C : Normally Open and Normally Closed Contacts ( non-latching )

All Relay Contact Ratings

120/250 VAC : 4A 30 VDC : 4A Relay response time 10mS typical

3. SPECIFICATIONS

Table 3.1

LKAT2 System Specifications ( subject to change without notice )

Main Output Full-Scale Measuring Range

mA output max. burden : 10V mA output max. loop/load resistance : 500Ω V output min. load resistance : 100kΩ

Linearity Error * ±0.1% of full-scale

Response Time (td) * di/dt Accurately Followed * Frequency Response * Switch selectable low-pass filter :

Mains Voltage Sensitivity ±0.001%/V

* At DynAmp reference conditions : Ambient 25°C ± 2°C (77°F ± 4°F) / Mains 18 – 36Vdc

±5kA to ±150kA ( Contact factory for full-scale measuring ranges > 100kA )

0mA ±20mA max. 4mA +20 & -12mA 0V ±1V

0.2V -0.6V to +1V 0V ±10V

≤ 50 µs 500 A/µs

No filter / 330hz / 660hz

MAIN STATUS INDICATORS

problem detected or mains power lost.

over current (+5…+100% of full-scale) or reverse current (-5%...-100% of full-scale).

Red indicates measured current exceeds Trip

current exceeds Trip Setpoint or mains power lost.

Installation, Operation and Service Manual LKAT2 +24V

OPTIONAL DISPLAY

Digital Display of Bus Current in kA units

3 ½ Digit Green LCD ±2% Full-scale

GENERAL

Input Power

be connected without any wiring changes)

Working Voltage: Signal Output to Metering Unit

450Vrms

ENVIRONMENTAL

Operating Ambient Temperature Range of Metering

-10°C to 60°C

Operating Ambient Temperature Range of Measuring Head

-20°C to 80°C

(-4°F to 176°F)

Environmental rating: Measuring Head and cable connection at Head

Environmental rating: Metering Unit and cable connection at Metering Unit

Table 3.1

LKAT2 System Specifications ( subject to change without notice ), continued

OPTIONAL PROTECTION EXTENSIONS ( PE )

PE Full Scale Measuring Range

independently and isolated from main output)

PE analog output configuration and performance specifications

PE Over / Reverse Current Trip Setpoints -Qty. (2) Field configurable

Displayed Value (configurable) DC or True RMS

NOTE: Optional display reduces maximum ambient temperature of metering unit to 50°C

(any voltage within the specified range can

Burden on Mains (max) 30 VA

Low Voltage Circuit Working Voltage: Bus to Metering Unit Low Voltage

Circuit Working Voltage: Mains Supply to Metering Unit

Low Voltage Circuit Working Voltage: Mains Supply to chassis 264Vrms

(scaled

±5kA to ±200kA

measuring ranges > 100kA )

Same as Main output above with all configuration and scaling independent from main output

Function and specification same as Main Over / Reverse above with independent LEDs, configurations, scalings and outputs

( Contact factory for full-scale

18 - 36Vdc

1500Vdc

264Vrms

Working Voltage: Output to chassis 450Vrms Isolation : Head surface to signal outputs 6000Vrms for 1 minute Isolation : Mains supply to signal outputs 1000Vrms for 1 minute Isolation : Mains or signal output to chassis 2000Vrms for 1minute Installation Category II Pollution Degree 2

Unit Location

(14°F to 140°F)

IP65

Installation, Operation and Service Manual LKAT2 +24V

Measuring Head Weight

Typically 1 to 6 kg (3 to 13lbs.)

Metering Unit Weight ( Typical )

Typically 3kg (7lbs.)

Standard Length Head Connection Cables (2)

10m (33 ft.)

Meter Unit on opposite end

Standard Length Signal Output Cable (1)

30m (100 ft.)

unterminated on opposite end

Standard Length Power Input Cable (1)

10m (33 ft.)

unterminated on opposite end

F.S. Bus Current (kA)

5 to 50

100

Corner Frequency (kHz)

2.248

1.873

1.606

1.405

1.249

1.124

-40

-20

0.01 0.1 1 10 100

NORMALIZED BUS CURRENT

20 Log(I / IFS) ; (dB)

Table 3.1

LKAT2 System Specifications ( subject to change without notice ), continued

PHYSICAL

Optional custom lengths may be available up to 50m (164 ft.)

Optional custom lengths are available

Custom lengths are available

Figure 3.1

LKAT2 Frequency Response

Normalized LKAT Bandwidth

Cable fixed to Measuring Head with connector for

Connector for Metering Unit on one end,

Connector for Meter Unit on one end,

Normalized Frequency f/fc ; fc = 1 1 2 .4 x 10

( A / s ) / I F S ( A )

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4. INSTALLATION

4.1 HANDLING PRE CAUTIONS

LKAT2 Systems should be handled with the same care as any precision measuring instrument. Severe jolts or bumps to the Measuring Head or Metering Unit may cause movement of internal parts, and possibly a malfunction. Personnel involved in the

installation should be familiar with the technical terms, warnings, and instructions in this manual, and all plant safety rules, and be able to follow these.

The complete system should be inspected for shipping damage at the earliest opportunity. Visible damage must be reported to the carrier immediately. Concealed damage (not evident until the system is operated) must be reported to DynAmp, LLC immediately.

4.2 INST ALLATION CONSIDERATIONS

Read the following before mounting the head:

1. The Measuring Head is designed to be installed on high voltage bus bars. All interconnection cables must be safely routed away from bus bars and high voltages. Do not allow any interconnection cable to contact bus bars or high voltages. Ignoring the installation precautions and warnings can result in severe personal injury or equipment damage.

2. Always follow all local and plant safety procedures when the unit is to be installed on a live bus.

3. Choose a mounting location for the head where the ambient air temperature does not exceed the specified temperature limits. The LKAT doors or outdoors, but should be kept away from extreme heat and solvents. Head installations in direct sunlight are not recommended, as excessive temperature rise could result in measurement error or damage to the head enclosure. If the head is to be installed in an especially harsh environment, please contact the factory to discuss special requirements.

4. No part of the head or Metering Unit should be submerged under water.

5. The head must be installed with proper polarity. An arrow indicates the direction that conventional bus current must flow through the aperture (+) to (-). No damage will occur if the head is reversed, but the system output will indicate current flow in the reverse direction.

6. Measuring Heads are shipped in matched halves. Make sure that the same serial number is present on both halves of the Measuring Head and the Metering Unit. The two head halves should mate squarely and evenly without forcing or twisting.

7. The Measuring Head is not grounded; however, the head cables should be disconnected from the Metering Unit prior to installation or maintenance to minimize the possibility of electrical shock.

8. Measuring Heads are shipped with mounting hardware. The mounting screws may require adjustment for appropriate position and holding force on the bus. Refer to Outline & Mounting – LKAT

Measuring Head drawing.

Whenever possible, the head should be installed on the longest straight run of the bus that is available in an area free of other bus structures. The status accuracy diagnostics LEDs and relay contacts indicate proper operation in a given head location.

Measuring Head may be located in-

Installation, Operation and Service Manual LKAT2 +24V

3/16” hex wrench (included with Measuring Head)

Drill, drill bits, mou nting hardware, screwdrivers, wrenches, etc.

Cable puller, cable ties, ladder, etc.

4.3 OFF-BUS FUNCTIONAL CHECK (OPTIONAL)

After unpacking the LKAT2 System (but prior to installation), the following functional check of the system is recommended:

1. Locate a convenient temporary power source for the LKAT be in the location where the system will be installed. The power source must be in the range 18-36Vdc. The system draws a maximum of 30 volt-amperes.

2. Refer to the drawing “Wiring Diagram, LKAT

System” included at the end of this manual. Attach a suitable connector to the unterminated end of the input power cable assembly for connection to the power source to be used for this check.

3. Connect the Measuring Head cables A & B to the Metering Unit.

4. Connect the power input cable assembly to the Metering Unit and energize the unit.

5. Observe the LEDs on the Main pc board assembly. If the LEDs light green, the system is functioning properly. If LED (Accuracy Diagnostics “AD”) lights red, skip to “Troubleshooting an Accuracy Diagnostics Fault Indication” in the “Theory of Operation” section of this manual. If LED (Trip 1) lights red, make measurements and complete the form “LKAT

Diagnostic Measurements Form – Zero Primary Current” and contact the

factory.

Refer to Form 1 – Zero Primary Current. Allow the system one hour to stabilize prior to making measurements. Make measurements and record data shown on the form. File the completed test form for future reference. It is OK to make these measurements away from location where the LKAT

System will be installed, but this should be noted on the form.

System. This may or may not

4.4 MEASURING HEAD INSTALLATION

The head halves are mated together around the bus. The Measuring Head is comp rised of two “L” shaped halves. Each half is identified with a serial number w hi ch must match followed by an “A” or “B”. One interconnection cable exits from each corner box on each half. The two halves are held together by four locking screws which are installed after the head is securely positioned around the bus bar.

When the Measuring Head is installed on a running (“horizontal”) bus, the head interconnection cable assemblies should exit the corner enclosures on bottom side of the bus bar. This reduces chances of ingress by pollutants and minimizes heating of the head electronics by the bus.

For rising (“vertical”) busses, the head interconnection cables may be located on any side of the bus, depending on mechanical and thermal considerations. Avoid mounting boxes above vertical bus. The head should be mounted on the bus bar so conventional (+) to (-) current flows in the direction of the arrow on the Measuring Head.

The following tools and materials may be required for installation:

Installation, Operation and Service Manual LKAT2 +24V

Front Vie w

Installation Confi gura t ion Side View

The following is the recommended sequence for installing the Measuring Head:

1. Refer to the Outline and Mounting drawing for the Measuring Head at the end of this manual.

2. Determine the position where the Measuring Head will be installed. Bus bar(s) should be free from grease and dust for the best adhesion of the LKAT

90° mounting angles to the

bus bar(s).

3. Connect the head cable assemblies to the Metering Unit.

4. Remove the backing from the adhesive foam strips on the fiberglass mounting angles. Align the mounting angles in position on the corners of the bus bar in the desired location.

5. Position the two “L-shaped” head halves around the bus and the mounting angles. Mate the two halves, pressing them together until the tubes bottom out on the elbows.

6. Install the four locking screws on the outside of the square tubes adjacent to the place where the head halves split apart. Do not over tighten the locking screws. Refer to Outline & Mounting – LKAT

Measuring Head drawing.

7. Tighten the bus mounting screws a few turns at a time in a circular pattern around the aperture of the head, on the front side, then on back side of the head. For most applications, the head should be centered on the bus bar. The bus mounting screws should press against the foam tape on the mounting angle surface on the outside of the bus bar. Refer to Outline & Mounting – LKAT

Measuring Head drawing. Do not

overtighten bus mounting screws.

8. Route the head interconnection cables away from the bus and other high voltages.

9. Connect the power cable assembly to appropriate power source and LKAT

Metering Unit.

4.5 M E TE RING UNIT INSTALLATION

The location of the Metering Unit should be determined by the following factors:

1. Ambient air temperature must stay in the specified range at all times.

2. The location should not be exposed to direct sunlight.

Installation, Operation and Service Manual LKAT2 +24V

3. The location should be within reach of the head cables supplied with the system. Standard head cable length is 33 feet (10 meters). Extra-long head cables may also be ordered for special applications.

4. Route interconnection cables away from bus and other high voltages.

Refer to Metering Unit Outline & Mounting drawing at the end of this manual. Anchor the cabinet in the desired location after ensuring adequate cable reach.

5. Connect Measuring Head cable assemblies to the Metering Unit.

6. Refer to the LKAT

System Wiring Diagram. The output cable assembly consists of 20AWG shielded twisted pair cable (8 pairs) with 17 (one contact position in output connector is unused) position circular connector on one end, and stripped, tinned wires on the other end. The twisted wire pairs are jacketed with black and white PVC. Each pair has the pair number imprinted on the jacket. Connect the output cable assembly wires to the appropriate points in the process electronics system.

7. A 3-conductor power cable is supplied with the system. Connect power cable to the Metering Unit.

4.6 SYS TEM CHE CKO UT

Recheck all wiring connections against the drawings to ensure proper installation. Energize the LKAT

System. Confirm that the green status LEDs are illuminated. If accuracy diagnostic LED lights red, skip to “Troubleshooting an Accuracy Diagnostics Fault Indication” in the “Theory of Operation” section of this manual

Energize the rectifier to the desired test current. Calculate the expected Metering Unit output signal magnitude at the test current.

The measured Metering Unit output signal magnitude should be equal to (or very close to) the expected value that was calculated.

If the Digital Display option is included in the Metering Unit, the displayed kA level should also be equal to (or very close to) the expected value that was calculated.

Refer to “SPECIFICATIONS” section of this manual for more information. Photocopy the appropriate LKAT

Diagnostic Measurements Forms. Form 1 is for diagnostic measurements at zero bus current (with the Measuring Head on or off the bus). Form 2 is for diagnostic measurements with the Measuring Head installed on the bus with the bus energized. Follow the directions to measure and record necessary information.

• These forms are intended to help keep accurate records of LKAT2 functional tests.

• This information may prove valuable in the event of a malfunction.

• These measurements do not constitute system calibration.

• Space is provided for the recording of three sets of readings.

• Voltages may vary slightly with temperature extremes.

• System performance will typically remain within nominal specifications when measured

levels fall within the acceptable limits shown on the forms.

• Levels must be measured and recorded under test conditions shown on the forms.

• The Metering Unit cover must be open during system checkout, as all measurements

are made inside Metering Unit on Main pc board terminal blocks. The cover should remain firmly closed during normal operation.

Always complete these forms in full before contacting the factory.

Installation, Operation and Service Manual LKAT2 +24V

4.) Record Serial Numbers.

(+) DMM

(-) DMM

ACCEPTABLE

RANGE

DATE

____/____/___

DATE

____/____/____

DATE

____/____/___

Output

Full-Scale

Serial Numbers :

Metering Unit ______________________

Measuring Head

A Half : ______________________

B Half : ______________________

Form 1

LKAT2 Diagnostic Measurements Form – Zero Primary Current

Instructions:

1.) Ensure that the Metering Unit is energized and both head halves are mated and connected to the Metering Unit.

2.) Ensure that head is off bus, or that bus is de-energized.

3.) Measure and record the information below (make additional copies of this form as needed).

TEST CONDITIONS:

ZERO PRIMARY CURRENT (Head may or may not be installed on bus);

SYSTEM must be ENERGIZED for AT LEAST ONE HOUR.

+12V

(±0.5V)

+12V

(±0.5V)

MEASURE

Hall

Supply-A

Hall

Supply-A

LKAT

P4-1 P4-3

P4-2 P4-3

+15V

supply

-15V

supply

Input

Current

Loop

Burden at

P4-4 P4-5

P4-6 P4-5

P1-1 P1-2

P1-3 P1-2

P2-1 P2-2

P2-3 P2-2

P3-1

P3-2

+15V

(±0.5V)

-15V

(±0.5V)

(±5mV)

10.2V max

Installation, Operation and Service Manual LKAT2 +24V

4.) Record Serial Numbers and Current Loop Burden Resistance (Ohms).

LKAT2 SYSTEM must be ENERGIZED for AT LEAST ONE HOUR.

Within

Input A2

Within

Output

Scale

Serial Numbers :

Metering Unit ______________________

Measuring Head

A Half : ______________________

B Half : ______________________

Form 2

LKAT2 Diagnostic Measurements Form – Energized Primary Bus

Instructions:

1.) Ensure that the Metering Unit is energized and both head halves are mated and connected to the Metering Unit.

2.) Ensure that head is on bus and that bus is energized.

3.) Measure and record the information below (make additional copies of this form as needed).

TEST CONDITIONS:

ENERGIZED PRIMARY BUS ;

MEASURE

Hall

Supply-A

Hall

Supply-A

+15V

supply

-15V

supply

Input

(+) DMM

(-) DMM

P4-1 P4-3

P4-2 P4-3

P4-4 P4-5

P4-6 P4-5

P1-1 P1-2

P1-3 P1-2

P2-1 P2-2

P2-3 P2-2

ACCEPTABLE

RANGE

+12V

(±0.5V)

+12V

(±0.5V)

+15V

(±0.5V)

-15V

(±0.5V)

±25mV of

Input A1

Within

±25mV of

Input B2

Within

±25mV of

Input B1

DATE

____/____/___

DATE

____/____/____

DATE

____/____/___

Current

Loop

Burden at

P3-1 P3-2

10.2V max

Full-

Current Loop Burden Resistance (Ohms)___________

Installation, Operation and Service Manual LKAT2 +24V

5. THEORY OF OPERATION

5.1 GENERAL

The LKAT2 System uses open-loop, open-path (OLOP) technology to convert the magnetic field associated with a current carrying conductor into an isolated milliampere current loop output. This output is scaled to be proportional to the primary conductor current. In addition, a local digital display of the primary bus current (in kiloAmperes) is visible when the optional RMS Display pc board is added to Metering Unit.

Each Measuring Head is a sealed unit and is not designed for repair in the field. However, a working knowledge of the LKAT accurate diagnosis in the event of problems.

5.2 OLOP TECHNOLOGY

The term “open-loop” means that the magnetic circuit does not generate an opposing magnetic field to null the field produced by the primary conductor inside the Measuring Head. The term “open-path” indicates that the sensor is an air-core design, without magnetic core material.

The LKAT (magnetic flux density) around any closed path is equal to µ current)”. In practical terms, this means that integrating a closed path around a primary conductor will yield a value proportional to the net primary current.

This integration is implemented using a specific array of Hall Effect ICs. The LKAT effectively minimizes errors typically present in other open-loop sensors: zero drift, thermal drift, position sensitivity, and susceptibility to external magnetic fields. The absence of a magnetic core practically eliminates errors due to saturation, hysteresis, and core set (remanence) commonly associated with ferrite material.

A generalized block diagram of the LKAT

System operation is based on Ampere’s Law, which states: “the line integ ral of B

System theory of operation will help facilitate timely and

I (permeability multiplied by

System

System is shown in Figure 5.1.

Installation, Operation and Service Manual LKAT2 +24V

Hall IC Array

Head Half A

Signal

Conditioning

& Scaling

Hall IC Array

Head Half B

Signal

Conditioning

& Scaling

SENSOR HEAD

+12Vdc

+15Vdc

POWER SUPPLY PCB

Summing Amplifier

Gain Adjust

Isolation

Current

Loop

DC Bias

Metering Unit PCB Assy

DC Bias

Comparator

Status LEDs

Relay Contacts

DC Bias

Comparator

Status LEDs

Relay Contacts

PROTECTION EXTENSIONS

PCB (OPTIONAL)

Note: This PCB is very

similar to the Main PCB.

Display Gain &

Zero Adj.

RMS to DC

Digital Display

Display PCB (Optional)

19.99

Figure 5.1

Block Diagram of the LKAT2 System

5.3 SYSTEM FUNCTIONAL DESCRIPTION

The flux density associated with the primary current is sensed by arrays of Hall ICs in the Measuring Head. The outputs of these devices are summed and filtered, then transmitted to the Metering Unit where these signals are dc biased and scaled. The Accuracy Diagnostics status LEDs and relay contacts are driven by a signal input that compares the various Hall groups with voltage setpoints. When the Hall group signal exceeds the reference, the green LED will go out and the red LED will illuminate. The relay coil will change state under the same conditions. The Trip Setpoint LEDs and relay contacts operate in a similar manner.

Installation, Operation and Service Manual LKAT2 +24V

Main PCB LED is a RED / GREEN the Accuracy Diagno s t ics status LED. This LED indicator and Main PCB relay CR2 contacts may be used to monitor the following conditions:

• Measuring Head imbalance

• Power supply failure

• Measuring Head disconnected

• Sensor electronics failure

• Other circuit failures causing loss of measurement accuracy

Occurrence of one or more of the conditions above will change the state of the CR2 relay coil, changing the state of the contacts and changing the LED indication from green to red. Refer to the section “Troubleshooting an Accuracy Diagnostics Fault Indication” in this section for more information about determining the cause and eliminating a fault condition.

Refer to section “Failsafe” / “Non-Failsafe” Configuration in this chapter for more information about Alarm Relays.

5.4 LKAT2 METERING UNIT

Refer to drawings in the back of this manual. Input power connects to the Power Supply pc board assembly. The power supply pc board

includes a non-replaceable slo-blo type fuse, in-rush and overcurrent protection, as well as MOV overvoltage clamping. The power supply provides outputs of ±15Vdc and +12Vdc required by the system electronics. These outputs connect to the Main pc board assembly via a short wire harness.

Connections to the Measuring Head are made via the Main pc board assembly.

5.5 LKAT2 MEASURING HEAD INTERCHANGEABILITY

DO NOT connect LKAT Classic or LKAT Plus Measuring Head to an LKAT2 Metering Unit – doing so will damage the Measuring Head.

LKAT Metering Unit. However, the LKAT

Measuring Heads of various sizes will operate properly when connected to the LKAT2

System is factory calibrated as a system. As a result, optimal measurement accuracy is achieved when the Metering Unit is connected to the head it was calibrated with, and installed on the size bus bar it was designed for.

5.6 TROUBLESHOO TING AN ACCURACY DIAGNOSTICS FAULT INDICATION

A problem may be detected when the LKAT2 System is energized with A and B head cables connected to the Metering Unit. When the Main PCB AD status LED illuminates RED and / or Main PCB CR2 status relay coil changes state, a possible fault condition has been detected. This is true whether or not the Measuring Head is installed on the bus. The following table is intended to help the user determine and eliminate the cause of the fault.

Installation, Operation and Service Manual LKAT2 +24V

OFF

Open

System operating

OFF

Closed

X X No input power

Verify input power connection

OFF

Closed

DC power supply

Verify DC power on main PCB

Head halves disconnected

Verify head interconnections at Metering Unit

Adjust position of head for green ON, red OFF

Measure head input signals at zero bus substitute known good Measuring Head

OFF

Closed

X X Other problem

Contact factory

IMPORTANT NOTE

DynAmp, LLC assumes no responsibility for the accuracy of LKAT2 Systems ca librated by any person other than a DynAmp, LLC Technician.

Table 5.1

Troubleshooting an Accuracy Diagnostics Fault Indication

Possible problem

Main

Green LED

Contact

Red LED

BUS ON

BUS OFF

P3-3 to P3-5

Action / Check

OFF ON Closed X X OFF ON Closed X Head imbalance

OFF ON Closed X X

Measuring Head malfunction

current; output should be < 5mVdc;

5.7 SYSTEM CALIBRATION OVERVIEW

DynAmp does not specify exact required intervals of calibration for its products. The end user of the product is responsible for identifying the appropriate interval between

calibrations. The intervals should be determined based on the following factors:

• Requirements of a Quality Management System

• Accuracy and permissible limits of errors

• Purpose and usage

• Experience with similar products

• Manufacturer’s recommendations

• Stability of the product

• Past history

• Other characteristics of the product

Reference: "ISO/IEC 17025:2017, General requirements for the competence of testing and calibration laboratories" and Laboratory Accreditation Bureau "Guidance for Documenting and Implementing ISO/IEC 17025:2005 and Laboratory Guidance."

As a guideline, DynAmp recommends a 24-month interval of calibration for all permanently installed products and a 12-month interval of calibration for all products used in portable applications.

Calibration may be performed as:

• Field Calibration (On Process Bus)

• Field Calibration (On Test Bus)

• Factory Calibration

Installation, Operation and Service Manual LKAT2 +24V

IMPORTANT NOTE

g calibration must review

Generally, system calibration compares the output of the device under test (“DUT”) to a reference.

The best calibration method is to return LKAT bus in a very controlled environment with extremely stable and accurately measured current. This re qu ires that the LKAT

Measuring Head be removed from process bus. The head and

Systems to the factory for calibration on a test

associated Metering Unit must be returned together, and should have the same serial number. The signal output and input power cable assemblies do not need to be returned for factory calibration. Specific details of factory calibration are beyond the scope of this manual.

Field calibration is possible using a 0.1% accurate current measurement system, such as the DynAmp LKP, LKCO or Opti-Cal as a reference. Due to significantly larger size and mass, it may be difficult to install a comparably rated LKP Measuring Head in on the same bus as the

LKAT

. An existing LKCO or DynAmp’s portable Opti-Cal system is better suited for this

purpose. Field calibration accuracy depends on the stability of the test bus current, the accuracy of the

reference current measurement system and ammeters, as well as the linearity of the LKAT

System.

5.8 CALIBRATION ADJUSTMENTS

To avoid injury and/or electrical shock, personnel performin and observe all hazard warnings and safety precautions stated throughout this product manual.

LKAT

System calibration adjustments are summarized below. All Bias and Zero adjustments are made at zero bus current. All Scaling and Gain adjustments are typically made at full-scale current. Refer to pc board assembly drawings at the end of this manual for location of switches and

potentiometers, as well as tables listing proper switch settings. Except for step 1) below, each table is shown on the appropriate pc board assembly drawing.

Forms 1 and 2 are used to check and record system power supply and channel voltages. Main PCB – Current Loop Output

• Output Bias (coarse) : SW2C…SW2F

• Output Type : SW6

• Output Gain (coarse) : SW3

• Output Bias (fine) : Trimpot

• Output Gai n ( fin e ): Trimpot

Main PCB – Trip 1 Setpoint

• Trip 1 Protection Polarity : SW2A and SW2B

• Trip 1 Setpoint : Trimpots (medium) and ( fine)

Installation, Operation and Service Manual LKAT2 +24V

NOTE

The Optional PE and/or RMS Display pc board assemblies may be added, configured and calibrated in the field . In this case, the Main pc board asse mbly output signal is used

Optional PE PCB – Current Loop Output

• Output Bias (coarse) : SW4

• Output Type : SW5

• Output Gain (coarse) : SW1 and SW2

• Output Bias (fine) : Trimpot

• Output Gain (fine) : Trimpot

Optional PE PCB – Trip 2 & 3 Setpoints

• Trip 2 Protection Polarity : SW3

• Trip 2 Setpoint : R33 (medium) and R46 (fine)

• Trip 3 Protection Polarity : SW3

• Trip 3 Setpoint : R34 (medium) and R47 (fine)

Optional RMS Display PCB – Display

• Decimal Point position

• DPM Mode

• RMS Signal Conditionin g Options : SW1F, G, & H ( SW1-6, 7, & 8)

• Input Scale Factor : SW1E (SW1-5)

• Input Attenuation : SW1A, B, C, & D (SW1-1, 2, 3, & 4)

• DPM Gain (fine) : R12

as the reference output signal with the LKAT2 System measuring normal bus current.

Installation, Operation and Service Manual LKAT2 +24V

New Trip Current

New V

Old Trip Current

X Old V

Example:

Old V

STPT

= 7V

Old Trip Current

= 70kA

New Trip Current

= 80kA

80kA

X 7V

= 8V (New V

STPT

)

70kA

TP6

TP2

TP3

Use TP0 for zero volt reference (circuit common) for voltage measurements for trip setpoint

5.9 FI E LD CO NFIGURATION OF TRIP SETPOINTS

Trip setpoints may be re-configured on site for any level between 5% and 100% of full-scale. The trip polarity may also be re-configured on site. However, the Accuracy Diagnostics trip setpoint should not be adjusted without consulting the factory.

Refer to assembly drawings for the Main pc board and PE pc board (optional) included at the end of this manual. To change trip polarity adjust SW2A and SW2B according to the table on the assembly drawing.

The trip setpoint is proportional to the current where the trip will occur: “Trip Current” – from Metering Unit nameplate.

The easiest method to check or change trip setpoints is to use the DynAmp LKAT MUT system which is specifically designed to simplify this process as well as verify proper operation afterwards.

To configure the trip setpoint without the LKAT MUT or complete test stand, the following method can be used.

Refer to Table 5.2, “Trip Configuration Details”. Measure t he existing setpoint voltage (V use the equation below to calculate the new setpoint voltage. Adjust coarse and fine potentiometers to produce calculated New V

STPT.

STPT

);

STPT

Table 5.2

Trip Configuration Details

Trip Circuit V

(Main)

(PE)*

configuration.

STPT

(Main)

(PE)*

Location

Medium Adjust Trimpot

R91 R98

R33 R46

R34 R47

* Optional

NOTE

The LKAT2 is supplied with factory configured trip setpoints configured as specified in the LKAT2 Worksheet at the time of order. If the trip setpoints are reconfigured in the field, the customer must realize that the trip setpoints shown on the LKAT2 Metering Unit nameplate will no longer be correct. In this case, DynAmp suggests that the nameplate be changed to reflect the new trip setpoint (following reconfiguration).

Fine Adjust Trimpot

046404 E

Installation, Operation and Service Manual LKAT2 +24V

No low pass filtering

OFF

5.10 EARTH GROUNDI NG

Here is a detailed description of the Earth Ground connection path:

1. The input power cable assembly connects CONN4 to the mains power.

2. Refer to the LKAT

3. The earth ground wire connects from CONN4 to the FLTR1 metal case only. The FLTR1 metal enclosure is not connected to copper foil traces on the Power Supply PC Board Assembly, the steel standoff inserts or the steel PCB mounting bracket.

4. The Earth Ground connection is only used to shunt common mode noise to earth.

There is no electrical connection from any part of the LKAT Main PCB or its optional daughter PCBs to Earth / Chassis ground or the steel PCB mounting bracket or panel. There is no electrical connection between the steel PCB mounting bracket or panel to Earth Ground.

System Wiring Diagram and wire system accordingly.

IMPORTANT NOTE

5.11 CONFIGURING THE LOW PASS FILTER

The LKAT2 System includes a two pole configurable low pass filter. This filter may be enabled without affecting the scaling of the output in the pass band. The frequency response of the

LKAT Refer to the Main pc board assembly drawing at the end this manual. To configure the low

pass filter, set switches as shown in the table below.

330 Hz cutoff OFF OFF ON OFF 660 Hz cutoff ON ON ON OFF

without the low pass filter activated is shown in Figure 3.1.

Table 5.3

Low Pass Filter Switch Settings

SW1 position A B C D

Installation, Operation and Service Manual LKAT2 +24V

Non-Failsafe Metering Unit Configuration

POWER ON

TRIPPED

5.12 “FAILSAFE” / “NON-FAILSAFE” CONFIGURATION

The LKAT2 System relay outputs are failsafe as factory configured. When the system is energized, all relay coils are energized and all contacts change state; that is, open contacts close and closed contacts open. During any alarm condition, relay coils de-energize, which changes the state of the relay contacts.

In the failsafe configuration, loss of input power to the LKAT alarm relay coils. This causes the relay contacts to change state and indicate an alarm condition.

For some applications, the user requires that Trip1 to be “non-failsafe”. That is, the system should not produce an alarm when there is loss of input power. Alarm conditions other than loss of input power must continue to result in an alarm. Trip1 relay contacts can be configured for Non-Failsafe operation. AD relay contacts are failsafe only. Trip2 and Trip3 relay contacts (present on optional PE PCB assembly) are failsafe only.

Table 5.4 shows the status of the LKAT

alarm relay contacts. The alarm relay contact

condition is shown as it exists at the customer connections to the metering unit.

To convert the LKAT

System Trip1 to non-failsafe operation requires modification of the Main pc board assembly, and modification of an internal wiring harness. Contact factory. Refer to the Main pc board assembly drawing at the end of this manual.

Table 5.4

LKAT2 Alarm Relay Status

(As found at Customer Connection to Metering Unit)

Metering Unit de-energizes the

Alarm Name

Contact Set

POWER

OFF

POWER ON

NORMAL

Trip2 P9-6 to P9-8 Closed Open Closed P9-6 to P9-7 Open Closed Open

Trip3 P9-3 to P9-5 Closed Open Closed P9-3 to P9-4 Open Closed Open

Trip1

P3-6 to P3-8

P3-6 to P3-7

Open

Closed

Open Closed

Closed Open

AD P3-3 to P3-5 Closed Open Closed P3-3 to P3-4 Open Closed Open

ALARM

Installation, Operation and Service Manual LKAT2 +24V

This Page is Intentionally Blank

Installation, Operation and Service Manual LKAT2 +24V

IMPORTANT NOTE:

If Main pc board LED (AD Status LED) is illuminated RED and / or the status relay

manual.

CAUTION

To avoid the risk of shock and electrocution, always disconnect all cable assemblies

6. MAINTENANCE & SPARE PARTS

6.1 PERIODIC MAINTENANCE

As is true with any electronic system, proper maintenance will tend to prolong the service life. DynAmp, LLC recommends the following program be performed at the recommended interval to prevent or detect damage to the LKAT Always use appropriate measures to correct any problems found. Following the suggested maintenance schedule may assist in early diagnosis of problem(s) to minimize repairs and down time.

coil de-energizes, a fault condition may exist in the LKAT2 electronics. When this occurs, the system may require immediate attention. Refer to “Troubleshooting an Accuracy Diagnostics Fault Indication”, in the “Theory of Operation” section of this

System and to ensure reliable performance.

6.2 ANNUAL MAINTENANCE

Refer to the “Calibration” section of this manual for calibration intervals. If possible, perform the steps described in section titled “System Checkout” in the “Installation”

section of this manual at least once per year to verify performance of the LKAT may help to prevent or detect damage to the system and to ensure reliable performance. Use appropriate measures to correct any problems found. If LKAT

System equipment is exposed to extreme temperatures, DynAmp, LLC recommends these steps be performed during the hottest time of the year.

In addition, the following steps should be performed once each year as part of annual maintenance:

1. Visually inspect Measuring Head and interconnection cable for evidence of severe

overheating, cracks, separation of bonded surfaces, or excessive corrosion. Record any suspect conditions.

2. Inspect the Measuring Head mounting screws and adjust as needed.

3. Visually inspect Metering Unit for evidence of severe overheating, corrosion, or

condensation. Record any suspect conditions and take appropriate action.

4. Clean as necessary; remove any oil or grease with a mild detergent. Do not use

abrasives or strong chemical solvents as they may damage the cables or erase the silkscreen markings from the Metering Unit.

5. Disconnect power to the system before servicing.

System. This

before performing any cleaning on the Metering Unit.

Installation, Operation and Service Manual LKAT2 +24V

Angle, LKAT2 Mounting 100mm

46039

8 (each)

Screw , LKAT2 mounting SHCS 1/4-20 X 3”

46028

2 (each)

Spare System

Complete System (Head & Metering Unit calibrated as system)

TBD

Metering Unit

TBD

Measuring Head

TBD

6.3 S PARE PART S

The following table lists the minimum recommended quantities for spare parts for the LKAT2 System. As spares are used, replacements should be ordered. Since continuous operation of high-current measurement systems is often critical, stocking spare parts should be given high priority.

Some cable assemblies for the LKAT cup connectors assembled with adhesive-lined shrink tubing covering the connector shell. If connector(s) are severed from the associated cable assembly, field installable replacement connectors may be purchased. These connectors may also be installed after routing head interconnection cables in conduit. Over-molded replacement cable assemblies may be purchased for the power input and output cables. Head cable connector(s) must be replaced by field installable type(s), or with a new head. Refer to Spare Parts List Table 6.1

The LKAT

System Measuring Heads require special repair procedures and materials. However, the heads are very reliable and should require little or no repair over its service life. Please refer to the nearest authorized DynAmp, LLC service center for information on repairs.

DESCRIPTION ITEM NO. RECOMMENDED

System include circular connectors. Others use solder

Table 6.1

Spare Parts List

QUANTITY

* Item number same as original system

** Contact DynAmp, LLC .

Installation, Operation and Service Manual LKAT2 +24V

Assembly: LKAT Protection Extensions PCB

75A108587

7. DRAWINGS

Table 7.1

Drawing List

DRAWING TITLE

NUMBER

REVISION

Wiring Diagram: LKAT2 System (Low Voltage Version) 83B109318 E

Assembly: LKAT2 Metering Unit (Low Voltage Version) 84B109279 B Assembly: LKAT2 Main PCB 75A109352 B

Assembly: LKAT RMS Display PCB 75A108588 C

Outline and Mounting: LKAT2 Measuring Head 02B109349 E Outline and Mounting: LKAT2 Metering Unit 02B109280 C

DynAmp LKAT2 Installation, Operation And Service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual