DynAmp LKP-100 Installation, Operation And Service Manual

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DynAmp, LLC

MODEL LKP-100

DIRECT CURRENT METERING SYSTEMS

Installation, Operation and Service Manual

Manual Item No. 041738

Rev. I

Grove City, Ohio 43123 USA Fax +1 614.871.6910 help@dynamp.com

3735 Gantz Road Phone +1 614.871.6900 www.dynamp.com

Installation, Operation and Service Manual LKP Series

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DynAmp, LLC WARRANTY

Items and components manuf ac t ur ed by Seller for permanent installation are warranted for two (2) years from the date of s hipment.

Items and components manuf actured by Seller for portable and temporary use in more than one location are warranted to be free from defects in material and work m anship for a period of eighteen (18) months from the date of shipment.

Items and components not manufactured and resold by Seller are warranted by their manufacturer.

Warranty repair shall be, at DynAmp’s option, in the form of repair or r eplacement of the defective items or components. Concer ning warrant y repairs , DynAmp will be responsible for DynAmp provided time, material and transportation costs (shipping or travel). Actual method of warranty repair / correct ion will be determined by DynAmp at DynAmp’s sole option. Such warranty repair shall constitute a fulfillment of all DynAmp, LLC liabilities in respect to said items and components. I n no event shall DynAmp, LLC be liable for consequential damages.

Information in this document is subject to change without notice. © 1997, 1998, 2000, 2002, 2003, 2004, 2006, 2008, 2011, 2016 DynAmp, LLC. All rights reserved. Reproduction for purposes other than operation and service without written permission of DynAmp,

LLC is strictly forbidden. This manual includes detailed drawings, installation, operation, service and maintenance. Users

should evaluate the information in the manual and their particular application. DynAmp assumes no liability for any incidental, indirect, or consequential damages arising fro the use of this documentation.

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

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The LKP Series 10 Channel includes the LKP-100 Metering Unit. This Metering Unit conforms to the latest Eur opean dir ectives and standards concerning safety and electromagnetic compatibility.

Application of Council Directive(s): 73/23/EEC, 89/336/EEC and 93/68/EEC.

Standards to which conform i ty is declared: EN50081-2 utilizing method EN55011: Radiated and Conducted Emissions for Heavy

Industrial Environments, Class A. EN50082-2: Radiated and Conducted Immunity Tests for Heavy Industrial Environments.

Safety Standards: EN 61010-1: Safety Requirements f or Elect r ical Eq uipm ent for Measurement, Control, and

Laboratory Use.

Note

According to EN 50082, the manufacturer m us t state the degradation of perf orm ance level acc eptable during immunity tests. Unless other wise noted in the manual or data sheet, DynAmp limits degradation during immunity tests for this equipment to < 0.5% FS for A-criterion tests.

Installation, Operation and Service Manual LKP Series

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Installation, Operation and Service Manual LKP Series

VOLTAGE

INSTALLATION

Hazard Warning!

GENERAL

HAZARDOUS

All installation, maintenance and service must be performed by qualified technicians who are familiar with the warnings and instructions of t his m anual.

The enclosure doors must remain closed at all times during operation to ensure safety of personnel. A set of keys is provided for locking the doors. Only authorized personnel or technicians should be allowed to open and service the unit.

Disconnect power to the system before servicing or r eplacing fuses. DynAmp does not assume liability for the custom er’s failure to comply with the

rules and requirements provided in this manual. Use of the equipment in a manner not specified by the manufacturer can

impair the protection provided within.

This equipment is designed to be connected to hazardous electric voltages. Ignoring the installation precautions and warnings c an result in severe personal 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 specificat ions must not be exceeded and the unit must be installed according to directions provided.

This equipment is intended for indoor us e only. It should be mounted in a wellventilated area, away from high heat, dust, and corrosive atmosphere. The ambient temperature must not exceed 55°C.

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 cat egory III and pollution degree 2.

Symbol Identification:

General definitions of saf et y symbols used on eq uipment and manual.

Caution/War ning : Refer to accompanying documents for instructions.

The CE mark proves the compliance of t he equipment with the requirements of the directives.

Installation, Operation and Service Manual LKP Series

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DynAmp, LLC Customer Support

For further assistance, cont ac t DynAmp Custom er Suppor t 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

Europe:

Telephone: +41 22.706.1446 Fax: +41 22.706.1311 8:30 AM to 5:00 PM Central European Time From last Sunday in October to last Sunday in March – 7:30 GMT to 16:00 GMT From last Sunday in March to last Sunday in October – 6:30 GMT to 15:00 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

1/98

15, 35

Rev A

Updated resistance chart table and drawing list

7/98

iii, 7, 35,

Rev B

Warranty, Installation, Communications, and Tech

04/00

27, 34

Rev C

Updated Accuracy Diagnostics & Spare Parts section

04/02

iii, 7

Rev D

Updated Warr anty and Installation paragraph

10/03

all

Rev E

Updated to DynAmp, LLC

12/04

vii, 1, 32,

Rev F

Update fuse precautions per ECR 1304

07/06

ECO 3166 update accuracy diagnostics drawings/list

09/08

PAR 10245 – Handling & Storage, ECR 1440Metering Unit Wiring

REVISION PAGE

all H

1,2,11,18 Rev I

Bulletins

Calibration Intervals / New Manual Format

ECO 3307 – Section 1 Safety, Installation Precautions,

06/11

10/16

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TABLE OF CONTENTS

Par. Title Page

1. SAFETY ____________________________________________________________________1

2. HANDLING AND STORAGE ____________________________________________________3

3. DESCRIPTION _______________________________________________________________5

3.1 OVERVIEW .......................................................................................................................... 5

3.2 MEASURING

3.3 METERING

3.4 CABLE .................................................................................................................................. 5

3.5 ELECTRICAL ....................................................................................................................... 5

4. SPECIFICATIONS ____________________________________________________________7

5. INSTALLATION ______________________________________________________________9

HEAD ............................................................................................................. 5

UNIT.................................................................................................................. 5

5.1 HANDLING

5.2 INSTALLATION

5.3 INSTALLATION

5.4 MAGNETIC

5.5 HEAD

5.6 COMPLETING

5.7 METERING

5.8 METERING

5.9 INITIAL

5.10 MAGNETIC

5.11 REVERSING

PRECAUTIONS ................................................................................................. 9

CONSIDERATIONS ................................................................................... 9

PRECAUTIONS (LIVE BUS) ..................................................................... 11

CONSIDERATIONS: MEASURING HEAD ...................................................... 12

INSTALLATION ....................................................................................................... 13

THE HEAD INSTALLATION ....................................................................... 15

UNIT INSTALLATION...................................................................................... 16

UNIT WIRING ................................................................................................. 18

SYSTEM CHECKOUT ........................................................................................... 18

CENTERING ................................................................................................... 19

CABLE EXIT DIRECTION ON MEASURING HEAD ...................................... 22

6. THEORY OF OPERATION _____________________________________________________23

6.1 GENERAL .......................................................................................................................... 23

6.2 MAGNETIC

6.3 SYSTEM

6.4 CIRCUIT

6.5 METERING

6.6 POWER

6.7 SYNC,

6.8 ERROR

6.9 COMPARATORS

6.10 PULSE

6.11 OUTPUT

6.12 ACCURACY

SENSOR (NULL DETECTOR) ........................................................................ 23

DESCRIPTIONS ................................................................................................. 23

FUNCTIONS ....................................................................................................... 24

UNIT................................................................................................................ 25

SUPPLIES ............................................................................................................ 25

PLL, AND RAMPS ................................................................................................... 25

AMPLIFIERS ......................................................................................................... 25

AND PULSE GENERATOR .................................................................... 25

TRANSFORMER DRIVERS ................................................................................... 26

CIRCUIT ............................................................................................................. 26

DIAGNOSTICS (OPTIONAL) ........................................................................ 27

7. MAINTENANCE & SPARE P ARTS ______________________________________________29

7.1 PERIODIC

7.2 ANNUAL

6.3 CALIBRATION

7.4 SPARE

MAINTENANCE ................................................................................................ 29

MAINTENANCE................................................................................................... 29

INTERVALS ............................................................................................... 30

PARTS ORDERS - ROUTINE OR EMERGENCY................................................... 31

Installation, Operation and Service Manual LKP Series

7.5 RECOMMENDED SPARE PARTS ...................................................................................... 31

6-7.

CUSTOMER SUPPORT ............................................................................................................ 32

8. RELATED TECHNICAL BULLETINS _____________________________________________33

9. DRAWINGS ________________________________________________________________35

DRAWINGS & TABLES

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

Figure 5.1 Typical Measuring Head Sectional Layout .............................................................. 9

Figure 5.2 General Guidelines for Locat ing Measuring Heads .............................................. 13

Figure 5.3 Proper Lifting Technique. ..................................................................................... 15

Figure 6.1 Magnetic Null Detector Diagram ........................................................................... 23

Figure 6.2 Functional Diagram of Four-Channel System ....................................................... 24

Table 4.1 LKP Series 10 Channel Specifications ................................................................ 7

Table 4.1 LKP Series 10 Channel Specifications, Continued ............................................. 8

Table 4.2 Typical Error At Zero Bus Current* ..................................................................... 8

Table 5.1. Measuring Head Resistance Chart ....................................................................... 17

Table 5.2 Form for Recording Channel Voltag e Measurement s ............................................ 21

Table 7.1 Spare Parts List * ................................................................................................ 31

Table 8.1 Technical Bulletins List .......................................................................................... 33

Table 9.1 Drawing List .......................................................................................................... 35

Installation, Operation and Service Manual LKP Series

1. SAFETY

This equipment is designed to be connected t o hazardous elect ric voltages. Ignoring the installation precautions and warnings can result in severe personal injury or eq uipm ent damage. Also, the equipment is heavy and requires s pecial handling pr ocedures to ensure the safety of both per sonnel and equipment itself. The following are g ener al guidelines that should be followed when installing, operation and servicing the Metering Unit and head.

• All installation, maintenance and service must be perform ed by qualified technicians

who are familiar with the warnings and instructions of this m anual.

• Always follow all local and plant safety procedures.

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

becomes necessary during servicing, the scope must be floating and not grounded. 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.

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

• Do not place in the rain, or under water, or submerge any part of the Measuring Head

or Metering Unit. The Measuring Heads are splash proof but are not waterproof.

• The surface on which the Measuring Head is mounted must be sound and capable of

supporting the head. Fasteners used m ust be capable of supporting the weight of t he head.

• Make sure that the cables are disconnected fr om t he head dur i ng i nstallation.

• The Measuring Heads are supplied with connector covers, which must be used

whenever the head cables are disconnected from the head. T he covers ar e neces sar y to prevent dust and water from entering the Measuring Heads. The covers also prevent fingers from contacting the connector pins during installation, which can carry hazardous voltages if the head is installed on a live bus.

• If the installation is to be made on a "live" bus, the Measuring Head cables m ust be

disconnected from the head. A condition hazardous to the Measuring Head and any person handling un-insulated cable-lead terminals will result if metal par t s of the head contact the bus, or sudden changes in t he bus current occur. Personal protective gear should be worn when reconnecting cable back to Measuring Head. Please refer to

installation section for head st or age on a l ive bus.

• Measuring Head should be electrically isolated from the bus bars. A ¼” ( 6m m )

minimum distance between the bus and window insulation should be maintained. This will insure electrical isolation of the head structure fr om the bus. The head itself is grounded via the cables to the Metering Unit. Refer to the “Installation Consideration” section of the manual for m or e details.

• An external circuit breaker or fuse with proper r at ing is required for branch circuit

protection when wiring the main circuit to this Metering Unit. Each Metering Unit must have its own breaker. Use a wire and breaker or fuse (time-delay) sized adequately for the maximum burden of 20 VA/kA of measured current. The wire should have an insulation rating of 600Vac and 80°C minimum tem per ature rating.

Installation, Operation and Service Manual LKP Series

• Replace fuses with correct type, size and value. All channel fuses are Type MDA time

delay fuses 3AB style, 1/4” x 1-1/4” (6.3mm x 32mm). Refer to the servicing instructions or spare parts list for more information on replacement fuses. Do not bypass the fuses or modify the electronics. Disconnect power to the System before replacing fuses. Failure to f ollow these instr uct ions will result in interm it t ent operation and premature failure and will void the warranty.

• Metering Unit enclosure doors and module covers must be present and r em ain closed

at all times during operation to insure safety of personnel. A set of keys is provided for locking enclosure doors. Only authorized personnel or technicians should be permitted to open and service the unit.

• Bus current must be zero when taking resist ance m eas ur em ents.

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

protection provided within.

DynAmp does not assume liability for the customer’s f ailure t o c om ply with the rules and requirements provided in this manual.

Installation, Operation and Service Manual LKP Series

2. HANDLING AND STORAGE

DynAmp products are engineered and manufactured for use in industrial environments. However, they contain sensitive electronic and mechanical components which may be damaged and fail if not handled and stor ed pr oper ly. All products m ust be handled and stored with the same care as any precision measurement instr um ent. Severe bumps or jolts may damage internal parts and cause malfunction or premature failure. DynAmp products are designed and assembled with conform al coat ing , shock mounting, and environmental seals, when appropriate or when specified. However, this protection requires that the product m us t be pr oper ly installed and operat ional before the protection is fully functional. Theref or e, adequate protection from humidity, shock, and temperature must be provided during handling and storage pr ior t o installation.

The handling and storage of equipment must be sufficient to meet the storage temperat ur e and humidity specifications of the product and to prevent any condensation or contact with water or any other liquid. The storage locat ion and cont ainer or crate must provide adequate protection from precipitation (rain, snow, ice) and direct water contact. Adeq uate 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 c ont ainer s or c r at es and cause water ingress. Storage in coastal or indust r ial areas s ubj ec t to salt-laden or corrosive air or areas of wind-driven sand or other abrasive dust must be adequate to prevent the deterioration or failure of shipping containers or crates and cause ingres s. Frequent inspection of stor age areas and storage containers or crat es is r equired to ensure proper storage conditions are being m aint ained.

If the shipping container or cr ate is opened and/or the equipment is removed for inspect ion prior to installation, the equipment m ust be repackaged in the original undamaged container or crate in the same manner as it was shipped to prevent environment al dam age or placed in a storage location that meets the required environmental and storage conditions.

General product storage tem per ature and humidity requirements: Storage Temperature: -40 to 70°C

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

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

For further assistance, cont ac t DynAmp cust om er s uppor t .

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3. DESCRIPTION

3.1 OVERVIEW

The DynAmp, LLC LKP-100 is a 10 channel metering system for ac cur ately measuring direct current in a bus up to 100 kA. The system consists of a Measuring Head, a Metering Unit, and two multi-conductor cables.

3.2 MEASURING HEAD

A magnetic core encircles the bus passing t hr ough the center of the Measuring Head. Magnetic null detectors are mounted in air gaps in the cor e. Each null detec t or is flanked by coils located on the magnetic core.

The Measuring Heads are constructed of c ast alum inum with a toug h powder coating finish, insulation from t he bus being provided by a 3/8 in. (9.5mm) layer of high-grade polymer.

The LKP 10-channel Measuring Head is provided with mounting feet as st andar d equipment. The mounting feet facilitate the mounting of the heads vertically on the floor or on a platform.

3.3 METERING UNIT

The Metering Unit is housed in a standard NEMA type enclosure (An IP54 upgrade is available). In addition to the electronic circuitry (housed within smaller modular units), the Metering Unit contains terminals for all external connec tions. The Metering Unit requires 120/240 Vac, 50 or 60 Hz power. Burden on the supply circuit will not exceed 2000VA under normal operating conditions (about 20VA/kA). A thermo-magnetic circ uit br eaker is mounted on the inside of the enclosure and serves as t he power on-off control.

3.4 CABLE

Standard interconnecting cables are supplied with each system such that t he dist anc e between the cabinet and the head is approximately 33 feet (10 meters) . Longer cable lengths are available - consult the factor y for details. Each of the individual conductors is tagged with a numbered label corresponding to a t er m inal block connection, providing an easy hookup to the Metering Unit. Keyed connectors are provided on the Measuring Head side of the cables to ensure correct hookup.

3.5 ELECTRICAL

Six outputs are provided by the system:

1.) A standard voltage output of 1 m V/ kA.

Installation, Operation and Service Manual LKP Series

2.) An optional secondary voltage output up to 1 volt at full scale (sc aled per c ustomer order).

3.) A current output of 1 Adc per 5 kA of bus current.

4.) A normally open (N.O.) contact for the Metering Unit over-temperatur e alarm, rated at 120 Vac, 6 A.

5.) A normally closed relay contact for accuracy diagnost ics out put. This feature is only available when the accuracy diagnostics option is ordered.

6.) Optional isolated shunt output. Scaling is per cus t om er order: 0-10V, 4-20mA available.

Installation, Operation and Service Manual LKP Series

Location

Repeatability Error Limits

±0.02% of full scale plus zero error. 

Line Voltage Sensitivity

±0.001%/V @ 120V ac

notes below.

Pollution Degree

4. SPECIFICATIONS

TABLE 4.1

LKP SERIES 10 CHANNEL SPECIFICATIONS

MODEL MAX. FULL-

SCALE RANGE*

LKP-100

100 kA Approx. 496 lb. (225 kg) Approx. 650 lb. (295 kg)

MEASURING HEAD

WEIGHT

METERING UNIT WEIGHT

Ambient Temperature Range of Measuring

-20°C to 55°C

Head

Ambient Temperature Range of Metering Unit

-20°C to 55°C

Humidity (head and Metering Unit) 85% maximum

AC Line Voltage at 50 or 60 Hz ±5Hz** 100,120,200,220,240 Vac +10%, -15%

Burden on ac Line: *** 20 VA/kA

Maximum Allowable Burden of Output Circuit 15 volts

Linearity Error ±0.03% of full scale f r om 5% to 100% of bus

current.

Temperature Sensitivity ±0.002%/°C

±0.0005%/V @ 240V ac

Measuring Head To Bus Isolation 12kVac for 1 minute with 25mm air g ap. See

Installation Category III

* Contingent upon DynAmp, LLC computer analysis of bus s ystem . ** The LKP systems are factory-set for the correct voltage and f r equency (50 or 60 Hz) per

customer order. To operate an LKP system at a different line fr equency than was ordered, move jumper JP1 (located on the control board inside each module) to the desired frequency. Refer to the wiring diagrams for changing the input voltage.

*** Size any external isolation transformers for 30VA/kA to avoid overheating the transformers

due to the presence of SCR generated har m onics on t he input ac line.

 When tested at 120 Vac, less than 1 V burden, 24° C ambient .

 Typical zero primary current errors ( bus equiv.) for each model are shown in table 4.2.  With bus passing through window insulation at 90° to the head.

Installation, Operation and Service Manual LKP Series

Current output:

1 A/5 kA, ±0.1% full scale

LKP 100 Metering Unit (all)

LKP-100 Measuring Head

Aperture Dimensions in. (mm):

NOTE

The Measuring Head window insulation rating is directly proportional to the clearance of the

insulation rating will be.

Models

Max. Core Set

LKP-100

±15 amperes

TABLE 4.1

LKP SERIES 10 CHANNEL SPECIFICATIONS, CONTINUED

OUTPUTS

Voltage output 1mV per kA of bus current, ±0.1% full scale

PHYSICAL

Overall Dimensions, in. (mm):

66 (1676)H x 48 (1220)W x 16 (406)D

44.6 (1134)H x 51.2 (1300)W x 11.8 (300)D

LKP-100 Measuring Head

30.5 (775) H x 46.1 (1170)W

head to the bus. For instance, a bus in direct contact with the window insulation of the head will have insulation rating of 6kV. A clearance of 1" increases the window insulation rating to 12 k Thus, the greater t he distance through the air between the bus and the head, the greater the

TABLE 4.2

TYPICAL ERROR AT ZERO BUS CURRENT*

* Excluding effects of exter nal buses. See sec t ion 5. 4 conc er ning the magnetic effects of

external buses.

Installation, Operation and Service Manual LKP Series

Figure 5.1 Typical Measuring Head Sectional Layout

5. INSTALLATION

5.1 HANDLING PRECAUTIONS

Even though the LKP Series systems are large and rugged, they should be handled with the same care as any precision measuring instrument. Severe jolts or bumps to the head or Metering Unit may cause movement of inter nal parts, and possibly a malfunction. It is also advisable to avoid supporting the head halves by the windows insulation. The window insulation is tough but brittle. Personnel involved in the installation should be

experienced with equipm ent of similar size and weight . They should also be familiar w i th the technical terms, warnings, and instructions in this m anual , and all plant safety rules, and be able to follow these.

The complete system should be inspected for shipping dam age at the earliest opportunity. Visible damage must be reported to the car r ier im m ediat ely. Concealed damag e ( not evident until the system is operated) must be report ed t o DynAmp, LLC imm ediat ely.

For all handling of the Measuring Head, use a lifting st rap capable of withstanding 1000lbs (454kg)

5.2 INSTALLATION CONSIDERATIONS

Read and follow the following considerations before mounting the head. These considerations and other mounting rest r ict ions and r ec om m endat ions ar e detailed in Technical Bulletin No. 9907.

A.) Choose a mounting locat ion where the am bient air temperature does not exceed 55°C.

The standard head is designed for indoor use only and should be k ept away from high heat and corrosive atmospheres. Also protect the head from direct sunlight as it causes the head temperature to rise, thus limiting the upper operating range in some

Installation, Operation and Service Manual LKP Series

applications. If the head is to be installed in a harsh environment , please discuss protective measures with the factory.

B.) The head should be protected from rain and snow. Also, no part of the head should be

submerged under water at any time.

C.) Temporar y and final support members should be nonmagnetic (f or example, aluminum

beams, struts or stranded c ables, or wood, fiberglass, or Phenolic where appropriate) to minimize distortion of the magnet ic field as seen by the head. It is recommended to keep any magnetic materials, str uc t ur al or ot her wise, at least 1 meter (3ft) away from the Measuring Head (2 meters recomm ended) . Refer to Technical bulletin No. 987, “Ferromagnetic Materials near LKP or LKB High Current Measurement System s” for further details.

D.) The head is designed to be s uppor t ed from the bottom. Never suspend the head by

the top half alone. If t he heads ar e t o be m ounted in a position other than vertical, each half of the head should be independently supported. T he lifting holes in the top half should be used for attaching ot her anti-tipping brackets. No additional drilling of the head is authorized, as damage may result.

E.) When m ounted, the two head halves of the head should be in the same plane so no

distortion of the part line will occur. No tension, twist, or excessive pressure s hould be applied to the part line.

F.) The head should be electrically insulated from the bus. A ¼” (6mm) minimum distanc e

between the bus and window insulation should be maintained. This will insure electrical isolation of the head structur e from the bus. The head itself is grounded

via the cables to the Metering Unit. Do not shor t bet ween the head structure and the bus to prevent serious damage or injury. For that reason, always disconnect

the cables from the head prior to installation or maintenance. Touching both an energized bus bar and grounded Measuring Head may result in electrical shock.

Each cable has a GRN/YEL wire that is used for head grounding. In order to electrically float the head above ground potential, the G RN/YEL wire (f rom each cable) must be disconnected at the Metering Unit. Note that for safety reasons, t he Metering Unit cabinet should be grounded at all times.

G.) Do not loosen any of the bolts that hold the head casting sections together. Doing so,

will compromise the seal between parts and allow water or contaminants to enter the head.

H.) The head must be inst alled with Current ar rows in the same direction as conventional

current flow in the bus. An arrow indicates the direction that conventional bus cur r ent must flow through the apertur e (+ to -). No damage will occur if the head is reversed, but the system will not produce an output.

I.) CAUTION: The par t -line insulation pieces (located on the mating surfaces of the head)

are brittle and contain sensitive electronic devices that can be easily damaged if one is not careful during

installation.

Installation, Operation and Service Manual LKP Series

WARNING

J.) Make sure that the serial number on the top half of the Measuring Head matches the

serial number of the lower half, and that t he halves go together squarely and evenly without forcing, twisting, or coc king.

K.) Try to mount the head in an area free of other bus bars. This is not an es sent ial

requirement if a satisfactory magnetic centering can be achieved.

L.) The final head position will be determined by the magnetic center ing process, so the

head support members should be temporar y at first. If a bus analysis has not been performed, the head should be geom etrically centered on the bus during the initial installation. If a bus analysis was performed, follow the recommendations for initial positioning, and perform the c ent er i ng process.

M.) After final magnetic centering, t he head m ust have adequate support.

Sudden changes or shutdown of bus current can induce hig h voltag es in open coil circuits inside the Measuring Head. This is a risk of shock if someone is in contact with the connector pins during the event. There is a slight possibility of connec t or or c oil damage if the Measuring Head is left un-operation (stored) for prolonged periods on a live bus with frequent fluctuations. The f ollowing precaut ionary measur es m ust be taken to prevent damage and risk of shock.

Best option is to leave the cables connected between Metering Unit and Measuring Head. Even if the Metering Unit is not powered, it will shunt induced currents in the coil and prevent high voltage from developing. If that is not feasible then use one of the following options:

i. The Measuring Head cable leads from the channel feedback coils must be short ed

together and isolated from all other c able leads and g r ound wire to pr event induced high voltages on the coil leads. Refer to the Head Resist ance Char t and / or schematics for coil circuit wire numbers.

Warning : Keep all exposed head cable leads from touching the bus, ground, or any support structures.

ii. Consult with DynAmp about using a shorting plug at each connector.

5.3 INSTALLATION PRECAUTIONS (LIVE BUS)

If the unit is to be installed on a live bus, the following precaut ionary measur es m ust be taken before installing the Measuring Head:

A.) Make sure that the cables are disconnected from the head during installation. B.) Always follow all local and plant safety procedures.

If the installation is to be made on a "live" bus, the Measuring Head cables must be disconnected from the head. The head is grounded via the cables. A condition hazardous to the Measuring Head and any person handling un-insulated cable-lead terminals will result if metal parts of t he head contact the bus.

Installation, Operation and Service Manual LKP Series

FREE BUS ANALYSIS

The general guidelines below should be applied only when a detailed analysis of your

s within your bus system at no charge.

assured that your system will function properly.

5.4 MAGNETIC CONSIDERATIONS: MEASURING HEAD

Although the LKP systems are designed and built for accuracy, stability, and reliability, these factors may be adversely affec t ed by the ar bit r ar y location of the Measuring Head without regard for magnetic fields. Secondary magnetic fields emanating from other sections of the bus being monitored or from other nearby buses may cause overheating. Currents from other bus es pr oduc e m agnetic fields, which can sometimes cause zero offsets and error s at low current levels. To guard against these problems, you can have a computer analysis of your bus system made, or you can f ollow the guidelines present ed in this section.

bus system is not available. DynAmp, LLC will perform one detailed computer analysis of the proposed location of t he Measuring Head Generally, this is done bef ore or at t he time the unit was ordered. In this way you are

NOTE: External magnet ic fields do not affect the basic accur acy of the equipment, provided channel voltage limits are not exceeded. The external field, however, will either add to or subtract from the flux in the Measuring Head core pieces. If the exter nal field is too large, the dynamic range of the channel amplifiers may be exceeded. If the subtract ive vector is larger than the vector set up by the bus cur r ent being measured, the channel current will go to zero and try to reverse. Since the LKP amplifiers can pas s current in the forward direction only, an error condition can exist. I n the other case, where the vectors are additive, the required current thr ough a given set of coils may exceed the dynamic range of the channel and result in enough heat to damage head components.

In most cases, it is possible to shift the position of the head relative to the bus to equalize channel currents, so that the dynamic rang e of any channel is not exceeded and heat distribution is more uniform around t he head. Equalizing channel currents in this way will prolong the life of the equipment. Measurement of channel voltages is the only way to make sure that the individual channel amplifiers are operating within dynamic-range limits. For further infor m at ion, r efer to the magnetic centering procedure in this section.

Whenever possible, the head should be inst alled on the long es t s t r aight run of the bus that is available in an area free of other bus struct ur es . G eneral guidelines requiring consideration when installing a Measuring Head are shown in Figure 5.2 (guidelines illustrated are to be considered as the minimum required distances). If the propos ed head location can be physically described by more than one of the diagrams (Figur e 5.2), a bus analysis should be performed.

For the guidelines of Figure 5.2 t o apply, the bus height-to-width ratio should equal the head aperture height-to-width ratio, within ±10%. T he r at io does not affect the accuracy of the measurement, but it does affect the loading of dif ferent sections of the head.

Installation, Operation and Service Manual LKP Series

OTHER BUS

2a (min)

BUS

2a (min)

(Center)

BUS

4a (min)

BUS

The head should be a minimum distance of 2a from another bus carrying equal or less current. If the other bus carries higher current, the distance should be greater, e.g., 3a.

The head should be located a minimum distance of 2a from a 90° bend in t he bus

If the head is to be installed on a U-sect ion of the bus, the distance between the parallel bus sections must be a m inimum of 4a, and the head should be centered between them.

If the head is to be installed on a T- sect ion of the bus, it should be located a minimum distance of 4a from t he j oining point .

a = maximum aperture dimension

Figure 5.2 General Guidelines for Locating Measuring Heads

5.5 HEAD INSTALLATI O N

Before actually installing the Measuring Head on the bus, t he head m ay be checked to make sure that no internal damag e oc cur red during shipment. This is accomplished by connecting the cables to the head (the head sec t ions do not have to be put together at this point), and performing the head resistance check as described late in this section. The

Installation, Operation and Service Manual LKP Series

NOTE

When installing the Measuring Head, protect the window insulation from impact, and

armored - protect it from abrasion and sharp edges.

head does not need to be mounted on bus. After the procedure is complete, the head should be mounted as explained next.

In general, the head can be installed vertically or horizontally. The Measuring Head is provided with feet for mounting to the floor or platform. The Measuring Head is also equipped with holes in the corners that can be used for lifting to aid in installation. After t he head is installed in place, these holes can be used to install anti-tipping str uts for head stabilization. However, the corner holes should never be used to hang the head for permanent installation without support for t he bottom half. If t he head is t o be m ount ed horizontally, then a platform must be used to ensur e even weight distr ibut ion of the head.

There are two connector fitt ing s on t he Measuring Head (one on each half). These fitt ings are not to be used for lifting. Proper lifting is accomplished by using eyebolts in the holes provided in the corners. Choker slings may be used around the head as long as strong lateral pressure on the edge of t he window insulation is avoided. CAUTION: The part-line insulation pieces (located on the mating surfaces of the head) are brittle and can be easily damaged if one is not caref ul during installation.

Mounting the head:

1. Make absolutely certain that the serial numbers of both halves of the head match, otherwise you may cause misalignment and unit failure.

2. Check the mating faces of the Measuring Head. Remove any dirt particles from the head part-line insulation and multi-conductor connector .

3. Mount the Bottom half of t he head on the floor or platform and secur e it in place temporarily. An arrow indicates the direction that conventional bus current must flow through the aperture (+ t o -).

4. Place the upper half of t he Measuring Head over the bus. Make sure that the halves go together squar ely and evenly without forcing, twisting, or cocking. If for some reason the head halves do not press tightly together , do not try to force the heads closer together as it might lead t o dam age. Check and remove any obstacles that may be preventing the head from assembling pr oper ly bef ore proceeding. Also, if ins talling multiple units make sure that the serial numbers match between the top and bottom halves.

5. Connect the head halves using the provided M8 bolts. Tighten the bolt s unt il snug - do not over tighten. Maximum torque allowed is 135 in.lbs. (15 Nm). Since t he bolts ar e stainless steel, the bolts should be lubricated befor e inst allat ion to prevent them from sticking or seizing. Molybdenum disulfide grease (“MolyLub”), or a dr y (“MolyCote”) type lubricant is recommended.

6. After f inal positioning of the head (see “Magnetic Centering” later in this section), secure the mounting feet per m anently to the floor or platform.

do not let the weight of the Measuring Head rest upon the window insulation as it can be easily damaged. Also, the interconnecting cable is of top quality, but it is not

Installation, Operation and Service Manual LKP Series

NOTE

You cannot get good ohmmeter r eading s if the head is on a live bus. The coils pick a high magnetic field.

Figure 5.3 Proper Lifting Technique.

5.6 COMPLETING THE HE AD INSTALLATION

With the head t emporarily installed and bus current off (or t he head r emoved from the bus for verification prior to installation) , c om plet e t he following steps.

A.) Connect the interconnecting cable direct ly to t he Measuring Head. Note that the

connectors are keyed and can only be connected one way. For instructions on reversing the cable exit direction for the top c able, r efer to the end of this section.

B.) Before connecting the other end of the interconnecting cable to t he Metering Unit,

perform the ohmmet er t es t s in t able 5. 1. The tests are made from t he open end of the cable (the Metering Unit side). Record these values for future reference.

up induced voltages from any rectifier r ipple. The Hall plate resistance changes in

Notes on Table 5.1 below:

1.) BUS CURRENT MUST BE ZERO when taking resistance measurement (or head removed form bus).

2.) Use high impedance DMM set on the lowest range appropriate for the m eas ur em ent. Measurements are made between cable leads listed, at Metering Unit end of cable. The resistance values shown in the table are for readings obtained with cable disconnected from the Metering Unit. Split channels 1 and 6 will read half t he

Installation, Operation and Service Manual LKP Series

resistance values when measured with all the cables connected to the Metering Unit. Also, note that the Hall device current supplies are connected in parallel for both Measuring Head halves when the cables are connected to the Metering Unit. The values in the tables are shown for each individual head half.

3.) These resistance readings ar e t he r oom temperature values of the copper channel coils. Measured values can be 50% higher if head is hot and/or cable length is long er than 30 feet.

5.7 METERING UNIT INSTALLATION

The location of the Metering Unit should be deter m ined by the following factors:

1. An indoor location where the ambient air temperatur e is within -20°C t o + 55°C at all

times should be used.

2. The location should be within reach of the head cable leng t h to be routed (33 feet or 10

meters).

3. The location should be approximately 8 feet (2.5 m eters) or more from high c ur r ent bus

bars. (Some installations have been made much closer to high current buses without difficulty, but the distance g iven is on the safe side.)

Anchor the cabinet in the desired location after ensur ing adequate cable reach.

Installation, Operation and Service Manual LKP Series

Measure Between

Approx. Value

LKP-100

Circuit

Cable to “A” Half of the

24 & 25

240-550

Hall Signal - Channel #4

32 & 36

600-800

Hall Current - Channels # 1-5

Cable to “B” Half of the

59 & 60

240-550

Hall Signal - Channel #7

63 & 64

240-550

Hall Signal - Channel #9

71 & 75

600-800

Hall Current - Channels # 6-10

TABLE 5.1.

MEASURING HEAD RESISTANCE CHART

Leads:

(Ω)

Head 3 & 16 18-22 Coil Circuit - Channel #1 A 4 & 15 9-11 Coil Circuit - Channel #2 5 & 14 9-11 Coil Circuit - Channel #3 6 & 13 9-11 Coil Circuit - Channel #4 7 & 12 9-11 Coil Circuit - Channel #5 8 & 11 18-22 Coil Circuit - Channel #6 A

18 & 19 240-550 Hall Signal - Channel #1 20 & 21 240-550 Hall Signal - Channel #2 22 & 23 240-550 Hall Signal - Channel #3

26 & 27 240-550 Hall Signal - Channel #5

Head

40 & 50 18-22 Coil Circuit - Channel #6 B 41 & 55 9-11 Coil Circuit - Channel #7 42 & 54 9-11 Coil Circuit - Channel #8 43 & 53 9-11 Coil Circuit - Channel #9 44 & 52 9-11 Coil Circuit - Channel #10 47 & 49 18-22 Coil Circuit - Channel #1 B 57 & 58 240-550 Hall Signal - Channel #6

61 & 62 240-550 Hall Signal - Channel #8

65 & 66 240-550 Hall Signal - Channel #10

Installation, Operation and Service Manual LKP Series

NOTE

If bus current is on, bus ripple or sudden changes in bus current level will induce from the head while wiring them to the Metering Unit.

5.8 METERING UNIT WIRING

Terminate all conductors fr om the head as shown in the interconnection diagrams in the back of this manual. As an aid to wiring, each conduc t or is ident ified by a numbered sleeve (or imprinted numeral), which corresponds to the cor r ec t t erminal destination. You should always use the wire numbers when making connections as wire colors may vary, or appear different under cer tain lighting conditions. If the wire ends get damaged and require re-stripping, use high quality wire strippers and set the strip length to 0. 39” (10mm).

Install and connect the output-monitor ing devices to the appropriate terminals at the Metering Unit (refer to inter c onnection diagram). If current output is used, remove the factory-installed jumper and connect the desired current output circuitry, using an adequate wire size. Make sure that the burden imposed by the wire is not excessive.

significant voltages in the feedback coils. Ther efore, the cables must be disconnected

Complete the wiring job by connecting the external power lines to terminals TS3-3 (NEUTRAL), TS 3-2 (PHASE), and TS3-1 (GROUND) in the Metering Unit.

Customer is responsible for supplying an external ci r cui t br eaker or f use with proper rating as required by local codes for branch circui t pr ot ection when wi ring the mains circuit to this Metering Unit. Each Metering Unit must have its own breaker. Use a wire and breaker or f use ( time delay) sized adequately for the maximum burden of 20 VA/kA of measured current. The wire should have an insulation rating of 600Vac and 80°C minimum temperature rating.

If an external transformer i s being used to supply power to the Metering Unit, consider sizing the transformer t o 30VA/kA. Over-sizing the transformer will keep its temperature rise to a mi nimum due to the harmonic rich content of t he AC current drawn by the Metering Unit .

5.9 INITIAL SYSTEM CHECKOUT

Recheck all wiring connections against the drawings to ensure pr oper inst allat ion. When they are satisfactory, turn on t he system by first closing the external breaker or disconnect (if used), and then the Metering Unit circuit breaker. Conf ir m t hat the POWER lamp is ON.

With the bus energized, the Metering Unit’s output in use should accurately measure the bus current. However, it is now necessary to take a complete set of channel voltage readings. These readings serve two purposes: One, to verify that all channels are operating properly; two, to aid in magnetic cent er ing of the head. With the bus current operating at its highest operat ing level, take two sets of readings, the first set taken immediately (to verify no condition exists that may cause damage to the LKP Metering Unit), and the second set af ter a 24-hour period of time (to ther m ally stabilize the head). Proceed as follows:

Installation, Operation and Service Manual LKP Series

CAUTION

Avoid operating the unit for an extended time with any channel output over 40 V. This will permanently damage the system. For voltages over 40 V, consult the factory.

A. The dc voltage range may be as high as 75 Vdc (see “D” below). Make cert ain t he

voltmeter being used is set to measure averag e dc volts in this r ange.

B. The measured bus and all other high current buses in t he vicinity (within a 10-meter

radius) should be operating at or near their highest levels. Note: All magnetic field sources will affect t he c hannel voltage readings.

C. Make a photocopy of table “Form for Recording Channel Voltage Measurements”. The

initial readings are made as instructed on the form, and are recorded in the individual blocks. Refer to the head schem atic drawing in the back of the manual, which graphically show the channel locations on the head.

D. Excluding the effects of external magnetic sources and assuming a full rated bus current,

each channel is expected (by calculation) to measure approximately 20 V to 35 Vdc. In practice, channel readings should be more on the order of 10 V to 30 Vdc, but that may not be achievable. A channel failure will usually be indicated by either a full-off (near zero), half-on (35-38 V) or full- on (70-75 V) condition.

E. If any of the channel readings do indicate tr ouble, r efer to Theory of Operations and

Maintenance & Spare Parts sections and resolve the problem; then proceed with "Magnetic Centering".

Note 1. Low Readings: A very low amplifier output voltage may be normal for cert ain channels; however, ripple can be as high as 3 V on a non-operating (f ull-off) channel. Thus, a very low reading (i.e., 1 V to 3 V, should be suspected as a possible problem; subsequent head movement or other magnetic change may show that the channel is operating properly.

Note 2. High Readings: The maximum allowable channel output of 40 V relat es to the maximum heat dissipation that the channel can safely handle. A reading of 30 V to 40 V makes a change in head position highly desirable. A reading exceeding 40 V makes a head position change necessary. A reading of 70-75 V indicates a full-on channel condition or a blown channel fuse, and requires immediate act ion to resolve the problem. A reading of 35-38 V when immediately adjacent channels are significantly different may indicate that one of the two SCRs in the channel has failed.

5.10 MAGNETIC CENTERING

The distribution of load, or heat, among all channels will be optimized by magnetic centering of the head relative to both the bus and the total magnetic environment of t he head. In general, this simply means moving the head so t hat c hannels with high voltage readings will be farther from t he bus , and c hannels with low readings will be nearer the bus. Whet her or not the head should actually be moved depends on three factors:

A.) The possible impracticality or difficulty of moving t he head bec ause of support-system

requirements, clearances available, etc.

B.) The necessity of moving the head because of voltage readings that are too high or t oo

low for certain channels.

C.) The desirability of m oving t he head t o obtain a better balance of channel voltages.

Installation, Operation and Service Manual LKP Series

Chan 1 = 25 V and Chan 6 = 12 V

Chan 3 = 36 V and Chan 8 = 12 V

CAUTION

Unless instructed otherwise by the factory, if t he head position must be changed it

impose stresses at the center joining points especially if one half is supported solely from the other half.

Study the initial voltage readings. First, if none of the readings are below 3V or above 30V, the head position may be left as is. If som e of the voltages are in the 31-40V range, a change should be considered. In some cases, a channel fuse might blow if the channel voltage is above 35 volts. In those cases, the head will have to be moved, or, if the head can’t be moved, then a higher rated f use can be installed. Using higher rated channel fuses shall be evaluated and approved by the factory only on a case-by-case basis. If any readings are over 40V, the head must be moved.

As the voltage readings are compared from channel-to-channel around the head, a pattern may be observed which indicates that a section of adjacent channels has higher-thanaverage readings, whereas the section directly across the bus has lower reading s. Looking for patterns of t his t ype will help in deciding how the head should be moved to obtain a better balance of channel voltages.

As a simplified example of optimizing the head position, assum e t hese readings are obtained for two pairs of directly opposite channels;

Note that it is not suff icient t o c onsider j us t a few channels; all channel readings must be considered for repositioning. However, for this simplified example the head would be raised (relative to the bus) to balance the channels 3 and 8 voltages, and moved horizontally (bringing channel 6 nearer the bus) to balance the channels 1 and 6 voltages . Note that (1) it would not be necessary to change the horizontal positioning since the channel 1 voltage is not excessive and (2) an absolute balance between opposing channels is unnecessary. Lowering the higher readings is m ore important than achieving perfect balance.

is important that it should be kept in a vertical plane if possible. The head can be mounted in a tilted plane without loss of accuracy. However, such mounting can

If it is necessary to tilt the head out of the vertical plane to achieve lower channel voltages, first make sure each half is independently supported at four points, and t hen car efully loosen the joining bolts. Independently move each half into the new position, visually align. Firm up the support system and re-bolt. A gap of at least ¼in. (7 mm ) must be maintained between any part of the head and bus to prevent possible buildup of a conductive dust path between them.

Using the initially recorded channel data, move the head position as necessary or desirable, observing the above precautions. Make spot reading s of the channels in question to confirm result s . When the spot readings ar e satisfactory, record their values and measure and record the values of all other channels in table 5.2. (Additional copies may be made to use for spot readings or trial runs.) Check the diagram t o s ee if the position is now satisfactory. Once balance is apparently achieved, it is advisable to let the system operate 24 hours to thermally stabilize the head. Then m ake any necessary adjustments and record the final position values on one of the book copies of table 5.2 and label accordingly. This data will be valuable for future troubleshooting or maintenance.

Installation, Operation and Service Manual LKP Series

TS1-

VOLTS

4 “ 2 5 “ 3 6 “ 4 7 “ 5 8 “ 6 41 “ 7 42 “ 8 43 “ 9 44

“

[ ] LOOP BURDEN (TS2 - 5 & 6):

[ ] LINE VOLTAGE (TS 3-2 & -3):

[ ] BUS CURRENT (kA):

TABLE 5.2

FORM FOR RECORDING CHANNEL VOLTAG E MEASUREMENTS

The following table is for the customer's convenience in keeping accurate records on his unit's performance.

If the channel voltages are measured and r ec or ded at least two hours after the system is energized has been properly "centered" electrically, the infor m ation may prove valuable in the event of any future malf unction.

It is a good idea to take an additional set of readings at the hottest time of the year, especially if the equipment is exposed to outdoor temperatures; space is provided for the recording of three set s of readings. NOTE: Although t he c hannel voltages m ay vary widely with temperature extremes, the accuracy will remain unaffected so long as each channel voltage falls within the limits of +3V to +40Vdc*.

Channel voltages are measured between terminals at the Metering Unit terminal block with the LKP meter unit in service on an energized bus.

INSTRUCTIONS

1. Record the channel measurements for every channel (make additional copies of this form as needed).

2. Supply the information called for below.

CHANNEL VOLTAGES READINGS

FROM

TERMINAL

TO COMMON

TERMINAL

CHANNEL

NUMBER

DATE

____/____/___

DATE

____/____/___

DATE

____/____/___

TS1-13 OR

TS1-52

Serial Number: ________________________

* Read notes in “Magnetic Centering” section of the manual carefully.

Installation, Operation and Service Manual LKP Series

5.11 REVERSING CABLE EXIT DIRECTION ON MEASURING HEAD

The cables are normally connected to the Measuring Head such that both cables point upwards. This is to facilitate routing t he cables t hrough conduit. However, there are instances when it is desirable to have the top cable on head half “A” (cable A) point downwards to allow for the installation of a shroud or weather protecting enclosur e dir ect ly above the head. The following procedure is for changing the top cable exit direction:

1. Disconnect ac power to the Metering Unit.

2. Disconnect the top cable from t he Measuring Head.

3. Note the original position of the guide pins and guide sockets (located at he corners of

the connector). Remove the guide pins and sock et s .

4. Gently pull out the connector pin housing being car eful to not pull excessively on the

delicate cable wires. Rotate the pin housing ½ a turn (180°) and r einser t into the connector.

5. Reinstall the guide pins and sockets in a pattern directly opposite the original position

(i.e. replace the sockets with the pins and the pins with the sockets).

6. Reconnect the cables to the head and reapply ac power to the Metering Unit.

WARNING:

WITH THE SYSTEM ON A LIVE BUS, THE AC POWER IS OFF, AND THE CABLE DISCONNECTED FROM THE HEAD, A SHOCK HAZARD EXISTS ON THE MEASURING HEAD CONNECTOR TERMINALS.

Installation, Operation and Service Manual LKP Series

6. THEORY OF OPERATION

6.1 GENERAL

Figure 6.1 Magnetic Null Detector Diagram

A thorough knowledge of the LKP system t heor y of operation is essential for eff icient troubleshooting. In figure 6.1 a portion of the Measuring Head is shown to illustrate t he magnetic-null principle used in all Series LKP current measuring equipment.

6.2 MAGNETIC SENSOR (NULL DETECTOR)

The magnetic sensor produces a voltage output proportional to the differ ence between the bus field and the feedback field. The s ensor output is amplified and is returned to the magnetic circuit in the for m of feedback current. This current is passed through 5000 turns to produce the feedback field.

The Measuring Head contains many magnetic sensors and feedback coils. Each set of sensors and the adjacent coils plus the associated am plifying section of the Metering Unit is termed a channel. Each channel responds nearly independently of the other channels to null the bus field in its own section of magnetic core. However, after passing through their respective coil groups, all channel currents are s um m ed t o produce the output current. This current, which is always in the ratio of 1 A to 5000 A of bus current, is passed through resistors or shunt s t o develop voltages for the meter and proportional outputs. The output curr ent it self is also available at the output terminals, which are jumpered if not used.

6.3 SYSTEM DESCRIPTIONS

Effects of s t r ay fields are nullified by joining a number of magnetic assemblies like the one just described in a closed path around the bus. Figure 6.2 shows four such assemblies

Installation, Operation and Service Manual LKP Series

(referred to as a 4-channel assem bly). A 4-channel system is used here as an illustration to simplify the drawing and explanation.

Figure 6.2 Functional Diagram of Four-Channel System

A magnetic null detector (sensor), high-gain current amplifier, and feedback coil are combined to form one channel, or cur r ent feedback loop. The function of each current loop (current I

, I2, I3, or I4) is to maintain a state of zero f lux in its relat ed s egment of the

iron core. A burden shunt placed in series with the total current ( I voltage E

, proportional to It. The common side of the shunt is r et urned to the four high-

gain current amplifiers. Since the bus current is directly proportional to the t ot al cur r ent I

bus current can be measured accurately by summing t he independent feedback currents (I

= I1 + I2 + I3 + I4). Therefore, the bus current is equal to 5000It. Moving the Measuring

Head with res pect to the bus will cause the values of the individual feedback currents to change but will not affect the t ot al cur r ent nor the accuracy of the measurement.

6.4 CIRCUIT FUNCTIONS

For the following discussion refer to t he “ Hig h Range Module Schematic” and system schematic drawings as appropriate. These dr awings are locat ed in t he bac k of the manual.

), develops an output

by a ratio of 5000:1, the

Before discussing the various circuit f unc t ions, a general description of the Metering Unit will be helpful. A Metering Unit may consist of one or more modular unit s . Each m odular unit contains the necessary circuitry for four channels of amplification. The Metering Unit also contains one main power transformer, c irc uit breaker, and the resistors or shunts t o develop output voltages. A 4-channel system is used here as an illustration to simplify the explanation.

Installation, Operation and Service Manual LKP Series

Beginning at a magnetic sensor in the Measuring Head, we can trac e t he signal path. To achieve a signal output in the presence of a magnetic field, the sensor (Hall plate) must be supplied a small exciting current. This current is c alled the control current (I approximately 6 mAdc for each sensor. The cont r ol cur r ent is derived from the 12 Vdc power supply in the Metering Unit. Since the sensor resistance is low (about 200 ohm), the sensor current is limited by two 1500-ohm resistor s (one on each side of the sensor). These resistors are located in the Measuring Head.

With a const ant dc cont rol current applied to a sensor in the presence of a dc magnetic field, the sensor output is a dc voltage pr opor t ional to the dc field. The sensor output voltage is conducted via the interconnecting cable to the Metering Unit, where it becomes the signal input.

), and it is

6.5 METERING UNIT

Although each modular unit contains only two circuit boards, it is comprised of several subcircuits. Each of these circuits is desc r ibed in the r emaining paragraphs.

6.6 POWER SUPPLIES

The LKP module contains a ±15 Vdc power supply, which powers only the on-board circuitry. The first m odule in the Metering Unit (also referred to as Module “A”) contains a 12 Vdc power supply for the Hall devices.

6.7 SYNC, PLL, AND RAMPS

The Metering Unit employs phase locked loop circuitry f or synchronization of the firing pulses of the SCRs. This particularly is an advantage when there is a high noise level present on the line voltage. The PLL circuitry consists of U101, U102, and associated circuitry. The line voltage is sensed at TP-4. I t is then filtered and sent to U112 to be converted into a square wave, and then to the PLL circuitry. T he out put of the PLL is a square wave and is present at TP-2. This signal is sent t o U104, U105, and RP101, which constitutes the ramp generator. The ramp generator out put consists of two downward sloping ramps, each 180 degrees out of phase from one another. Both ramps are sent to the quad comparators (U110 and U111), which are used to generate the firing pulses f or the SCRs.

6.8 ERROR AMPLIFIERS

The error amplifier circuitry consists of U106 through U109 and associated circuitry. T he error amplifiers serve two purposes, to am plify the Hall error signal and to filter it before sending it to the comparators.

6.9 COMPARATORS AND PULSE GENERATOR

The comparators consist of U110 and U111. They compare the amplified and filtered output of the error am plifiers to the two ramps generated by PLL and ramp gener ators.

Installation, Operation and Service Manual LKP Series

Two square waves are generated at the output of these comparators, one for t he pos it ive half cycle and one for the negative half, ( pins 1 and 2 of U110 for channel #1). One square wave will be used to trigger an SCR on the positive half of the waveform, and the other will be used for the other half c ycle. Since these s quare waves are too long in duration, they cannot be used directly to drive the pulse transform er dr ivers. The comparator output is "ANDed" (the mathematical product of a logic AND gate) with several pulses generated by the PLL. The output, (pins 3 and 4 on U113 for c hannel #1) will be a pulse train which will be used to drive the pulse transformer drivers. Pulse train tr iggering is an advantage when noise on the line turns off an SCR. The SCR is re-tr iggered allowing a minimum off time. Since these pulses are fixed and do not move, if they alone were used to drive the SCRs, the output would be very jumpy. This was smoothed by also ANDing the comparator with an integrated output of itself to give the output pulse tr ain infinite resolution.

6.10 PULSE TRANSFORMER DRIVERS

The pulse transformer drivers consist of U203, U204, and associated circuitry. A pulse train signal is sent into the drivers (pin 2 and 1 of U203 for channel #1). These drivers are open collector outputs, which drive the pulse transform er s ( T203A and T203B for channel

1). The secondary of the pulse tr ansformer develops a current pulse which drives the

associated SCRs (SCR pack #1 for channel #1).

6.11 OUTPUT CIRCUIT

Six outputs are provided by the system:

1.) A standard voltage output of 1 m V/ kA, at TS2-7 and TS2-8.

2.) An optional secondary voltage output, at TS2-9 and TS2-10.

3.) A current output of 1 Adc per 5 kA of bus current, at TS2-5 and TS2-6. The current output is available by removing a jumper connected across the TS2 t er m inals ( do not remove the jumper while the system is energized). Maximum allowable voltage drop across the terminals is 15 Vdc at maximum bus curr ent.

4.) A normally open (N.O.) contact for the Metering Unit over temperature alarm , r at ed at 120 Vac, 6 A, at TS2-11 and TS2-12.

5.) A normally closed relay contact for accuracy diagnost ics out put at TS2-17 through TS2-19. This feature is only available when the accuracy diagnostics option is ordered.

6.) Optional isolated shunt output. Scaling is per cus t om er order: 0-10V, 4-20mA available.

Burden resistors inserted in the series output cir cuit s hould be select ed with care. The wattage rating should be at least two times higher t han the calculated power dissipation. The burden resistor should have a low temperature coef ficient (25 ppm or better).

The Metering Unit is supplied with a two-pole circuit breaker mounted inside t he enclosur e, on the main panel.

Installation, Operation and Service Manual LKP Series

6.12 ACCURACY DIAG NO S TICS (OPTIONAL)

“ACCURACY DIAGNOSTICS” (AD) is a system that assures the user that most internal circuits are operating properly and it is also a diagnostic t ool. I t is made up of a number of circuits, monitoring conditions of many of the critical components, circuit s and connections within the current monitoring system. T he AD subsystem pr ovides relay contact s for the user to connect to his remote warning indicator. The AD diagnostic light emitting diodes on each Metering Unit module indicates proper operation of ass ociat ed cir cuit s. On some larger systems a red warning light mount ed on t he enclosur e door provides a simple visual warning (refer to wiring diagram for this feature).

The AD indicates the feedback circuit s ar e functioning properly and the system’s power supplies are within specifications. More specifically, this indicates the following conditions exist:

1. All channels have a core magnetic flux null:

a. All components in the circuits appear to be operating normally. b. Input fields are of the expected polarit y. c. Input magnetic flux appears balanced by feedback flux.

2. Power supplies are operating within acceptable ranges.

a. Mains input power is on. b. Hall plate sensor power supply output is correct.

With unidirectional LKP measur em ent systems, it is possible t h a t the AD circuits will give a warning indication when the system is operated at low rectifier current level, even though all circuits and components are functioning pr oper ly. T his warning at low levels is most likely to occur if the metering s ystem is ass ociat ed with one of s everal rect ifiers in the area.

The AD outputs indicate the present condition, having only a short time delay from an instantaneous condition. Although the AD does not monitor every possible error condit ion, it is an effect ive means of giving the user continual assurance of signal r eliability.

A. If the “Diagnostics Relay” is O.K. and the green LED indicators are all on:

Continue operating normally.

B. If the “Diagnostics Relay” indicates a warning and one or more green

indicators are off: This indicates there may be measurement err or s . Consequently the metering system should not be in full, automatic control of the rectifier. The AD relay contact out put is not intended to be the only monitor protecting the power rec tifiers. Primarily, it is expected that the customer wants to take immediat e ac t ion t o pr event unsafe operation. Unsafe operation could result if the meter ing s ystem is in the rectifier control loop and it erroneously produces a significantly lower output than is true. This might cause the rectifier control circuit t o inappropriately increase the power output, perhaps to overload levels for either the power supply or the process. So, if the metering system is in the control loop and the “Accuracy Diagnostics” indicates a potent ial problem , t he following actions are recommended: FIRST- Lock out control actions that could drive the rectifier output higher and SECOND-alert the operator .

Basically, each module inside the Metering Unit has four channel LEDs and 2 power supply monitoring LEDs. The following is a description of their functionality:

Installation, Operation and Service Manual LKP Series

Contact Terminals

Condition

TS2-17,18

TS2-18,19

Open

Closed

Fault condition, zero bus current*, or Metering Unit turned off

Closed

Open

Normal operation

A. Line: This LED indicates whether the supply voltage to the Metering Unit falls

within the specified limit of +10%, -15% of nominal. Significant chang es from

these values will cause this LED to turn off and trip the r elay. B. Hall P.S.: This LED indicates whether the Hall plate supply voltage supply

voltages fall with the specified operating limits. A failed Hall plate power

supply or a line voltage out of specification will extinguish this LED and trip the

relay. C. Channel LEDs: Each channel LED indicates the status of the corresponding

channel to aid quick troubleshooting. An extinguished channel LED can be

caused by the following:

a. A blown channel fuse;

b. a bad connect ion bet ween the cable and the Metering Unit or cable and

Measuring Head;

c. a bad Hall device in the head;

d. an open /or s hor t ed c oil in the head;

e. a prim ar y curr ent that exceeds the dynamic measuring range of the Metering

Unit;

f. the primary current is too low to activate all channels properly;

g. a strong external magnetic field causing a channel reversal.

Notes on items f and g above: A.) Under certain conditions, external magnet ic fields can reverse one or more channels in

the head. The accuracy indicators will show an error in those channels until the bus current level rises high enough to effectively turn on all channels (2-3Vdc is the minimum reliable channel voltage). This condition can cause f alse alarms. For more information on this, please ref er to technical bulletin TEC9908, “Resolving External Magnetic Field Errors”.

B.) In some installations, when the channel voltages are balanced, the c hannel LEDs will

remain on, even though the bus is turned down to zero. In this case, the accuracy diagnostics cir c u it is in an unstable condition and alarm faults, as indicat ed by the channel LEDs, should be ignored. Note that, in gener al, the Metering Unit’s 0.1% accuracy is only guaranteed when the primary bus current is above 5% of the full scale rating of the unit.

A relay contact output is available to connect to a remot e warning s ystem . The relay is closed under normal operating conditions and opens when a fault condition occur s . The output connections are available via a connector located on the left side of the Metering Unit. The terminals are desig nat ed on the appropriate interconnection diagram. T he terminals are used as follows:

* See notes above on zero bus current condition.

Installation, Operation and Service Manual LKP Series

IMPORTANT NOTE:

Keep organized, accurate recorded data (forms, etc.) fr om each Per iodic LKP system.

7. MAINTENANCE & SPARE PARTS

7.1 PERIODIC MAINTENANCE

As is true with any electronic circuitry, proper maintenance will prolong the service life. DynAmp, LLC recommends the following program be per formed at the recommended interval to prevent or detect damage to t he LKP system and to ensure continuing highaccuracy performance. Always use appropriate measures t o cor rect any problems found. Following the suggested maintenance schedule may assist in early diagnosis of problem(s) to minimize repairs and down time.

Maintenance. This information may be invaluable in troubleshooting a malfunc t ioning

7.2 ANNUAL MAINTENANCE

Perform the following steps at least onc e per year. I f LKP system equipment is exposed to outdoor temperatures, DynAmp, LLC recom m ends t hes e st eps be per formed during the hottest time of the year.

The following procedures should be perfor m ed at the recommended interval to prevent or detect damage to the LKP system and to ensure continuing high-accuracy performanc e. Use appropriate measures to correct any problems found.

A.) Repeat voltage measurements g iven in "Magnetic Center ing" procedure to ensure that

no significant change has occurr ed from the data recorded at startup. A large change in the amplifier output voltage of a given channel (compared to other channels) may indicate trouble in the channel. If all channels change pr opor t ionally, then t hat m ight indicate a change in the bus current. A lesser, but significant, change in a voltage measurement should be corrected by re-cent er ing the head. Remember that channel

voltages will vary slightly depending on the ambient temperature of t he head. B.) Measure and record the Hall device dc power supply voltage. C.) Visually inspect Measuring Head and interconnection cable f or evidence of severe

overheating or excessive corrosion. Record any suspect conditions. D.) Inspect and touch-up the seals between the window insulation and the aluminum frame

of the head. Reseal as necessary. E.) Inspect & replace if required the gasket between the cable connector and the mating head

connector.

F.) Inspect the condition of the pins and sockets and clean out any corrosion. G.) Visually inspect Metering Unit and signal converter(s) for evidence of severe

overheating, or excessive corrosion. Record any suspect conditions and tak e

appropriate action. H.) Inspect all bolts on the head and torque any that might have come loose. Observe

proper torquing techniq ues and spec s c ar efully.

Installation, Operation and Service Manual LKP Series

CAUTION

To avoid the risk of shock and elect r oc ut ion, always disconnect the AC power and Metering Unit.

I.) Clean the following items:

1.) Cables and external surfaces of Measuring Head and Metering Unit: Clean as necessary; remove any oil or grease with a mild detergent or cleaner

solvent. Do not use strong chemical solvents as they may damage the c ables or erase the silk-screening f r om the Metering Unit.

2.) Metering Unit interior (should only be perform ed after disconnecting power to the Metering Unit):

Dust and dirt can be removed by gently vacuum cleaning the unit. Be caref ul not damage the internal shunt. Solvents should never be used on any of the PC boards. The boards are coated with a protective conformal coating that can be stripped away by certain solvents.

J.) Check the electrolytic filter capacitors for seals that have been popped (degassed) or

are leaking electrolytic fluid. Replace if neces sar y.

K.) If the unit is equipped with a cooling fan and filter, then the filter should be cleaned or

replaced according to the manufac t ur er instructions.

head cables from the head before per forming any cleaning or service operation on the

Disconnect power to the system before servicing or r eplacing fuses.

6.3 CALIBRATION INTERVALS

DynAmp does not specify required intervals of calibration for its products. The end user of the product is r espons ible 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 recom m endations

• Stability of the product

• Past history

• Other characteristics of the product

Reference: "ISO/I EC 17025:2005, General requirements for the c om pet enc e of testing and calibration laboratories" and Laboratory Accreditation Bureau " G uidance for Documenting and Implementing ISO / IEC 17025:2005 and Laboratory Guidance."

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

Installation, Operation and Service Manual LKP Series

43790

Spare Parts Kit includes Module, Fuses and Bulb as one package

LKP Hi Range Module “A”

41413

Bulb, POWER ON light

42121

**Fuses, LKP-100 (channel fuse, 4 Am p) ( 5 per box)

12592

2 box

**Fuse, Module ac Supply (located on TS3-7, 6.25 Amp) (All)

12594

***Accuracy diagnostics PCB, (4) Channel main board (1 used on Module A)

***Accuracy diagnostics PCB, (2) Channel main board (1 us ed)

40402

***Accuracy diagnostics PCB, (4) Channel main board (1 used)

40355

7.4 SPARE PARTS ORDERS - ROUTINE OR EMERGENCY

Requests for spare part s should be directed to "Service" at DynAmp, LLC during normal hours. W hen contacting us, please present as much information as possible, such as the related equipment Model and Serial Numbers (available on the equipment tag); the required part name; its DynAmp, LLC item num ber (and other identifying or vendor number(s); and your time needs. An approved Purchase Or der Num ber should be given with your order.

7.5 RECOMMENDED SPARE PARTS

The following table lists the minimum recomm ended quantities* for spare parts for the LKP Metering Unit. As spares are used, replacements s hould be ordered. Since continuous operation of high-current m eas ur em ent s ystem s is usually critical, s t ocking spare parts should be given high priority.

A single module “A” kept on hand (see part num ber below), can be used t o replace either of the modules in the Metering Unit and guar antee quick, error fr ee r epair . Not e t hat a module “B” cannot be used to replace a module “A” but t he r everse is t r ue.

The LKP Series 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 near es t aut horized DynAmp service center for information on repairs.

TABLE 7.1

SPARE PARTS LIST *

DESCRIPTION ITEM NO. QUAN

Metering Unit

Kit, Spare Parts, LKP-100

Options

41314 1

* For one to five units, stock the quantities shown. For six or more units, a complete

system (head, cable, and Metering Unit) should be kept on hand.

** All Fuses are Time lag MDA style 3AB ¼” by 1 ¼” (6.3 mm x 32mm), 250 Volt *** Only required if accuracy diagnostics option is installed.

Disconnect power to the system before servicing or r eplacing fuses.

Installation, Operation and Service Manual LKP Series

6-7. CUSTOMER SUPPORT

For further assistance, cont ac t DynAmp Custom er 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

Europe:

Telephone: + 41 22.706.1446 Fax: +41 22.706.1311 8:30 AM to 5:00 PM Central European Time From last Sunday in October to last Sunday in March – 7:30 GMT to 16:00 GMT From last Sunday in March to last Sunday in October – 6:30 GMT to 15:00 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

Installation, Operation and Service Manual LKP Series

NUMBER

SUBJECT

Title / Description

TEC727)

Restrictions

Current Systems

systems (Accuracy Diagnostics)

Measurement Systems

Current Measurement systems

Systems Heads on Busses

hours

Measurement Systems

8. RELATED TECHNICAL BULLETINS

The following is a list of available technical bulletins that contain relevant infor m at ion in regards to high current m easur ements and the use of LKB systems. The technical bulletins are available upon request from DynAmp, LLC. Always consult the fact or y f or a list of the latest technical bulletins.

TABLE 8.1

TECHNICAL BULLETINS LIST

9908 Exter nal Fields Resolving External Magnetic Field Errors (replaces

9907 LKP/ LKB LKP and LKB Sensor Mounting Guidelines and

9905 LKP/ LKB Recommended Calibration Intervals for LKP or LKB High

9904 Diagnostics Self Diagnostics for DynAmp High Current Measurement

987 LKP/ LKB Ferromagnetic Materials near LKP or LKB High Current

749 Bus Analysis Computer Analysis of Measuring Head Locations In High

748 LKP/ LKB Guidelines for locations of LKP or LKB High Current

747 kWH Volt-hours times Ampere-Hours is NOT equal to Watt-

941 Bus Analysis Data required for Bus Analysis of Hig h Curr ent

Installation, Operation and Service Manual LKP Series

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Installation, Operation and Service Manual LKP Series

Wiring Diag r am : Harness Assembly, LKP Series 4 Channel

83C108030

Outline and Mounting: LKP-100 Measuring Head

02C108200

Wirin g Diagram: LKP-100 Metering Unit

83D108207

9. DRAWINGS

TABLE 9.1

DRAWING LIST

DRAWI NG TITLE NUMBER

Assembly: Control Circuit PC Board 75A108104 Assembly: Mounting Feet 02C108256

Totalizing Diagram: LKP Series Metering Units 02C108033 Assembly: Accuracy Diagnostics 07A109083 Schematic: LKP Accuracy Diagnostic Board 05B109034

Outline and Mounting: LKP Series 10-16 Channel Metering Unit 02D107892 Assembly: Supply & SCR Drive PC Board 75B108106 Schematic: LKP 4 Channel High Range Module 05B108074 Interconnection Diagram: LKP-100 02D108205

Schematic: LKP-100 Metering Unit 05D108206 Wirin g Diagram: LKP-100 Measuring Head 83B107970 Assembly: IP54 Fan Option 84D108154 Isolator Options Wiring Diagram 83D108167

DynAmp LKP-100 Installation, Operation And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

MODEL LKP-100

DIRECT CURRENT METERING SYSTEMS

1. SAFETY

2. HANDLING AND STORAGE

3. DESCRIPTION

4. SPECIFICATIONS

5. INSTALLATION

6. THEORY OF OPERATION

7. MAINTENANCE & SPARE PARTS

8. RELATED TECHNICAL BULLETINS

9. DRAWINGS