DynAmp LKP-8024 Installation, Operation And Service Instructions

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Model LKP-8024

DIRECT CURRENT METERING SYSTEMS

Installation, Operation and Service Instructions

Manual Item No. 041837

Rev. H

DynAmp, LLC 3735 Gantz Road Phone +1 614.871.6900 www.dynamp.com

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

Installation, Operation and Service Manual LKP Series

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Installation, Operation and Service Manual LKP Series

DynAmp, LLC WARRANTY

Items and components manufactured by Seller for permanent installation are warranted for two (2) years from the date of shipment.

Items and components manufactured by Seller 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 Seller 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 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 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.

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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Hazard Warning!

GENERAL

HAZARDOUS

VOLTAGE

INSTALLATION

Symbol Identification:

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

The enclosure doors must remain closed at all times during operation to ensure safety of personnel. A set of keys may be provided for locking the doors. Only

General definitions of safety symbols used on equipment and manual

authorized personnel or technicians should open and service the unit.

Disconnect power to the system before servicing or replacing fuses.

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

DynAmp does not assume liability for the customer’s failure to 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 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 specifications must not be exceeded and the unit must be installed according to directions provided.

These instructions apply only to retrofit kits installed on standard systems as originally supplied by Halmar Electronics or DynAmp. Customer is responsible to verify that the units are standard and do not have non-standard, customer modifications installed. Before installing the upgrade kit, document any modifications and contact DynAmp, LLC Service Department for further written instructions to deal with the non-standard circumstances.

The installer is responsible for any damages resulting from improper installation of upgrade kit.

This equipment is intended for indoor use 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.

Caution/Warning: Refer to accompanying documents for instructions.

Installation, Operation and Service Manual LKP Series

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DynAmp, LLC Customer Support

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

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

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REVISION PAGE

Page Change Reason For Revision Date

all Rev NEW 12/99 all A Warranty, Hazard Warning, Calibration Intervals, add

Technical Bulletin List, update drawing to current revision

19 B Deleted text regarding Hall Sensor power supply.

18, 24 C Updated Accuracy Diagnostics & Spare Parts section 04/02

all Rev D Update to DynAmp, LLC 12/04

22 Rev E Update per ECR-1245 – Remove 6-3. “Five Year Service”

and revised 6.2 (F.)

v, 1, 22,

24 29 G ECO 3166 update accuracy diagnostics drawings/list 09/08

Rev F Update fuse precautions per ECR 1304 07/06

12/00

3/01

11/05

all H

PAR 10245 – Handling & Storage, ECR 1440- Calibration Intervals / New Manual Format

06/11

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Par. Title Page

1. SAFETY _____________________________________________________________ 1

1-1. OVERVIEW ..............................................................................................................................1

2. HANDLING AND STORAGE _____________________________________________ 3

3. DESCRIPTION ________________________________________________________ 5

3.1 APPLICATION.........................................................................................................................5

3.2 SIGNAL CONVERTER RETROFIT KIT ..................................................................................5

3.3 ELECTRICAL ..........................................................................................................................5

4. SPECIFICATIONS _____________________________________________________ 7

5. INSTALLATION _______________________________________________________ 9

5.1 WARNING ...............................................................................................................................9

5.2 HANDLING PRECAUTIONS ...................................................................................................9

5.3 EQUIPMENT NEEDED ...........................................................................................................9

5.4 PRELIMINARY PRECAUTIONS .............................................................................................9

5.5 CONVERSION PROCEDURE...............................................................................................10

5.6 INITIAL SYSTEM CHECKOUT..............................................................................................11

6. THEORY OF OPERATION______________________________________________ 15

6.1 GENERAL .............................................................................................................................15

6.2 MAGNETIC SENSOR (NULL DETECTOR) ..........................................................................15

6.3 SYSTEM DESCRIPTIONS....................................................................................................15

6.4 CIRCUIT FUNCTIONS ..........................................................................................................16

6.5 METERING UNIT ..................................................................................................................17

6.6 POWER SUPPLIES ..............................................................................................................17

6.7 SYNC, PLL, AND RAMPS.....................................................................................................17

6.8 ERROR AMPLIFIERS ...........................................................................................................17

6.9 COMPARATORS AND PULSE GENERATOR .....................................................................17

6.10 PULSE TRANSFORMER DRIVERS .....................................................................................18

6.11 ACCURACY DIAGNOSTICS.................................................................................................18

7. MAINTENANCE & SPARE PARTS ______________________________________ 21

7.1 PERIODIC MAINTENANCE ..................................................................................................21

7.2 ANNUAL MAINTENANCE.....................................................................................................21

7.3 CALIBRATION INTERVALS..................................................................................................22

7.4 SPARE PARTS ORDERS - ROUTINE OR EMERGENCY ...................................................22

7.5 RECOMMENDED SPARE PARTS........................................................................................23

7.6 SERVICE ASSISTANCE .......................................................................................................24

8. RELATED TECHNICAL BULLETINS _____________________________________ 25

9. DRAWINGS _________________________________________________________ 27

Installation, Operation and Service Manual LKP Series

DRAWINGS & TABLES

Figure #

Title ................................................................................................. Page

Figure 6.1 Magnetic Null Detector Diagram ............................................................................15

Figure 6.2 Functional Diagram of Four-Channel System .................................................... 16

Table #

Table 4.1 LKP-8024 Specifications ...........................................................................................7

Table 5.1 Measuring Head Resistance Chart -LKP-8024 .......................................................13

Table 5.2 Form for Recording Channel Voltage Measurements ............................................. 14

Table 7.1 Spare Parts List* ...................................................................................................23

Table 8.1 Technical Bulletins List............................................................................................ 25

Table 9.1 Drawing List............................................................................................................27

Title ................................................................................................. Page

Installation, Operation and Service Manual LKP Series

1. SAFETY

1-1. OVERVIEW

This equipment is designed to be connected to hazardous electric voltages. Ignoring the installation precautions and warnings can result in severe personal injury or equipment damage. Also, the equipment may be heavy and require special handling procedures to ensure the safety of both personnel and equipment itself. The following are general guidelines that should be followed when installing, operation and servicing the meter unit and 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 installer is responsible for any damages resulting from improper installation of upgrade kit.

•

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.

•

Make sure that the cables are disconnected from the head during installation.

•

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 follow these instructions will result in intermittent operation and premature failure and will void the warranty.

•

Service must be performed by qualified technicians only. If use of an oscilloscope becomes necessary during servicing, the scope must be floating and not grounded. The meter 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.

•

If the installation is to be made on a "live" bus, the measuring head cables must 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 parts of the head contact the bus, or sudden changes in the bus current occur.

•

Bus current must be zero when taking resistance measurements.

•

Use wire and fuse (slow-blow) size adequate for the maximum burden of 20 VA/kA of measured current. The wire should have an insulation rating of 1000Vac and 80 - 105° C temperature rating.

Installation, Operation and Service Manual LKP Series

•

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 head or meter unit.

•

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

DynAmp does not assume liability for the customer’s failure to comply 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 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 wind-driven 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 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, contact DynAmp customer support.

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3. DESCRIPTION

3.1 APPLICATION

The LKP-8000 Series Replacement Signal Converter Kits permits an economical field

conversion and upgrade of an existing FM system. This conversion makes it possible to get many of the benefits of the new DynAmp LKP design, while keeping the existing enclosure, cables, and measuring head.

3.2 SIGNAL CONVERTER RETROFIT KIT

The LKP-8024 Retrofit Kit comes with step-by-step instructions, which affords easy conversion and minimum time off-line. The kit contains two LKP-8000 modules and a kit of parts required to complete installation. The modules replace the existing 24FM Metering Unit modules, and the remaining components are mounted along with existing system components.

3.3 ELECTRICAL

Four outputs are provided by the system:

1.) A standard voltage output 1mV/kA.

2.) An optional secondary voltage output (typically 1 volt at full scale).

3.) A current output of 1 Adc per 5 kA of bus current - Do not the system is energized. Maximum allowable voltage drop across the terminals is 15 Vdc at maximum bus current.

4.) A normally closed relay contact for accuracy diagnostics output.

5.) LED indicators for accuracy diagnostics.

open the current loop while

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4. SPECIFICATIONS

TABLE 4.1

LKP-8024 SPECIFICATIONS

Ambient Temperature Range Of

Signal Converter Location

-20°C to 55°C

Humidity (head and signal converter) 85% maximum

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

Burden on ac Line (maximum) 20 VA/kA

Maximum Allowable Burden

of Output Circuit

15 volts

Linearity Error ±0.03% of full scale from 5% to

100% of bus current.

Repeatability Error Limits ±0.02% of full scale plus zero error.

Temperature Sensitivity ±0.002%/V@120V ac

Line Voltage Sensitivity ±0.001%/V @ 120V ac

±0.0005%/V @ 240V ac

OUTPUTS

Current output 1 A/5 kA, ±0.5% full scale Voltage output 1mV per kA of bus current, ±0.1% full scale** Voltage output 1V at full scale bus current+ 0.1% full scale**

Accuracy Diagnostics Relay Normally closed. 60 VDC @ 2A

or 30 Vrms AC @ 2A

PHYSICAL

Overall Dimensions, in. (mm):

LKP Signal Converter Module

20.5 (521)H x 12.25 (311)W x 7.5 (191)D

Weight, lb. (kg):

Signal Converter Module 13.0 (6.0)

* The LKP systems are factory-set for the correct voltage and frequency (50 or 60 Hz) per customer

order. To operate an LKP system at a different line frequency 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.

** When calibrated with at DynAmp, LLC factory after retrofit kit installation. May be 0.5% if not

recalibrated. May be 0.2% if calibrated on site with a DynAmp portable measurement system.

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

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5. INSTALLATION

5.1 WARNING

The installer is responsible for any damages resulting from improper installation of upgrade kit.

5.2 HANDLING PRECAUTIONS

Review plant safety regulations, and make sure that personnel involved are aware of the hazards involved in working with and around high voltages.

The 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.

5.3 EQUIPMENT NEEDED

The following items are included in the LKP-8024 Retrofit Kit

a. 1 each - LKP-8000 High Range Module 1

b. 1 each - LKP-8000 High Range Module 2

c. 1 each - LKP-8024 Installation Parts Kit

Tools Required:

a. Flat blade screwdriver

b. 1 each - Wire strippers

c. 1 each - Digital Multimeter

1 each – OPTIONAL - 1.25 inch hole punch or steel-cutting 1.25 inch hole saw electric

drill and bits

NOTE

The drawings listed in the rear of this manual should be readily available during the 24FM Metering Unit conversion.

5.4 PRELIMINARY PRECAUTIONS

DynAmp, LLC recommends that all work be done on a de-energized bus. If this is not possible at your location, shut down the mains power to the 24FM, and observe the WARNINGS and NOTES that follows.

Installation, Operation and Service Manual LKP Series

WARNING

1.)

An electrical shock hazard exists at the barrier strips, even with the ac line power removed. To prevent possible personal injury and/or damage to the equipment, remove all wires from each FM modular unit, one wire at a time, and tape the ends of each wire.

Disclaimer: These instructions apply only to retrofit kits installed on standard systems as originally supplied by Halmar Electronics or DynAmp, LLC. Customer is responsible to verify that the units are standard and do not have non-standard, customer modifications installed. Before installing the upgrade kit, document any modifications and contact DynAmp, LLC Service Department for further written instructions to deal with the non-standard circumstances.

2.)

Disclaimer: Installed is responsible for any damages resulting from improper installation of upgrade kit.

NOTE

IN THE EVENT THAT WORK IS DONE ON A LIVE BUS, ANY WARRANTY, EXPRESSED OR IMPLIED MAY BE AFFECTED. CHECK WITH DynAmp, LLC FOR SPECIFIC DETAILS.

5.5 CONVERSION PROCEDURE

Conversion from the old 24FM Metering System to the new LKP-8024 is described in the following steps.

Prior to shutting down the old system, record the “As Found” channel voltages for comparison later to the “After Conversion” voltages.

a. Refer to Assembly Drawing. Observing the WARNING (above), remove all of the old

FM modular units from the enclosure, and install the new LKP-8024 modular units per drawing.

b. Disconnect (or cut) all wires from transformer TX-1, and cap the ends for safety. The

connections going to the head Hall plate supply terminals should also be removed and capped.

c. (Optional) Punch hole in enclosure door as shown in LKP-8024 Assembly drawing

Detail “1”. Use care to avoid damaging existing wiring on panel door.

d. Refer to Wiring Diagram. After the LKP-8024 modules are in place, connect wires

shown as dashed lines in wiring diagram.

e. Align wiring on top of existing wiring harness. Use cable ties to secure added wires to

existing harness.

f. If fault alarm indicator will NOT be installed, cut and cap wires routed to “power on”

and fault alarm panel lights.

g. Reconnect the main power to the signal converter, and close the circuit breaker. With

a digital Multimeter or equivalent, monitor the channel voltages on the main terminal strip to verify correct operation.

Installation, Operation and Service Manual LKP Series

5.6 INITIAL SYSTEM CHECKOUT

Recheck all wiring connections against the drawings to ensure proper installation. When they are satisfactory, turn on the system by first closing the external breaker or disconnect (if used), and then the LKP-8024 circuit breaker. Close the Signal Converter enclosure door, and confirm that the white POWER lamp is ON.

With the bus energized, the LKP-8024 outputs in use should accurately measure the bus current. However, it is now necessary to take a complete set of channel voltage readings to verify that all channels are operating properly. With the bus current operating at its highest operating level, take two sets of readings, the first set taken immediately (to verify no condition exists that may cause damage to the LKP-8024), and the second set after a 24hour period of time (to thermally stabilize the head). Proceed as follows:

a. Compare the “After Conversion” channel voltages to the “As Found” voltages. They

should closely match except for heating effects as the head warms up.

b. The dc voltage range may be as high as 75 Vdc. Make certain the voltmeter being

used is set to measure dc volts in this range.

c. The measured bus and all other high current buses in the vicinity (or in the facility)

should be operating at or near their highest levels. Note: All magnetic field sources will affect the channel voltage readings.

d. Make a photocopy of the “Form for Recording Channel Voltage Measurements” (table

5.2). The initial readings are made as instructed on the form, and are recorded in the individual blocks, which correspond to channel locations shown for the measuring head.

e. Excluding the effects of external magnetic sources and assuming a bus current of 100

kA, each channel is expected (by calculation) to measure approximately 18 V to 30 Vdc. In practice, channel readings should be more on the order of 10 V to 30 Vdc, but may not be achievable. A channel failure will

usually

be indicated by either a full-ff (near

zero), half-on (35-38 V) or full- on (70-75 V) condition.

f. Monitor the green alarm indicator LEDs. All LEDs should be turned on indicating that all

channels are working properly. The fault light is a push-to-test assembly and should light up when pressed. Continue to monitor the alarm LEDs for proper operation. As bus current is dropped to a minimum, the alarm relays will click off and one or more channel LEDs will extinguish (usually this occurs after a few seconds since there is a short delay designed into the alarm circuit). The fault light should turn on. As the bus current is increased, the relays should click on and the channel LEDs should turn on. The fault light should extinguish. Note that at low currents near zero, the channels are not fully switched on and the alarm LEDs’ status can be arbitrary. The alarm circuit will operate properly when bus current reaches 500A to 1kA, when channels are balanced. The alarm relay connection terminals should be checked using an ohmmeter for proper opening and closure of the contacts and also to ensure that the relays are wired according to the wiring diagrams and labels.

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 (only if the unit has an interconnection cable length greater than 30 feet), consult the factory.

Installation, Operation and Service Manual LKP Series

NOTES

1.) Low Readings: A very low amplifier output voltage may be normal for certain channels; however, ripple can be as high as 3 V on a non-operating (full-off) channel. Thus, a very low reading (i.e., 2 V to 3 V, should be suspected as a possible

problem; subsequent head movement or other magnetic change may show that the channel is good. A blown channel fuse can cause a low reading.

2.) High Readings: The maximum allowable channel output of 40 V relates 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, and requires immediate action 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.

NOTE

You cannot get good ohmmeter readings if the head is on a live bus. The coils pick up induced voltages from any rectifier ripple. The Hall plate resistance changes in a high magnetic field.

Installation, Operation and Service Manual LKP Series

TABLE 5.1

MEASURING HEAD RESISTANCE CHART -LKP-8024

Measure Between Leads: Desired Value Circuit

(Ohms)

CABLE TO “1” HALF OF HEAD

25 & 26 25-30 Hall Current - Channels 1, 2. 3

1 & 4 3-6 Hall Signal - Channel #1 5 & 6 3-6 Hall Signal - Channel #2

7 & 10 3-6 Hall Signal - Channel #3 27 & 34 10-12 Coil Circuit - Channel #1 28 & 35 10-12 Coil Circuit - Channel #2 29 & 36 10-12 Coil Circuit - Channel #3 39 & 40 Open Over temperature Thermostat

CABLE TO “2” HALF OF HEAD 25 & 26 25-30 Hall Current - Channels 4, 5, 6 11 & 12 3-6 Hall Signal - Channel #4 13 & 16 3-6 Hall Signal - Channel #5B 17 & 18 3-6 Hall Signal - Channel #6 30 & 34 10-12 Coil Circuit - Channel #4 31 & 35 10-12 Coil Circuit - Channel #5 32 & 36 10-12 Coil Circuit - Channel #6 39 & 40 Open Hall Current - Channels 5B through 1A

NOTES:

1. BUS CURRENT MUST BE ZERO when taking resistance measurements!

2. Use R x 1 ohmmeter scale. Measurements are made between cable leads listed, at Signal Converter end of Cable and with leads disconnected from TS1.

3. The resistance readings will be slightly higher if the cable is over 30 feet in length. These resistance readings are the room temperature values of the copper channel coils.

Installation, Operation and Service Manual LKP Series

TABLE 5.2

FORM FOR RECORDING CHANNEL VOLTAGE 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 recorded at least two hours after the system is energized has been properly "centered" electrically, the information may prove valuable in the event of any future malfunction.

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 sets of readings. NOTE: Although the channel voltages may 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 Signal converter 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

TS1-

27 28 “ 2 29 “ 3 30 “ 4 31 “ 5 32 “ 6 33 “ 7 34 “ 8

[ ] LOOP BURDEN (TS1 -37 & 38) [ ] LINE VOLTAGE: (TS1 -52 & 53) [ ] BUS CURRENT (kA):

TO COMMON

TERMINAL

TS1-35 OR

TS1-36

CHANNEL

NUMBER

DATE

____/____/___

VOLTS VOLTS VOLTS

DATE

____/____/____

Serial Number: ________________________

DATE

____/____/____

NOTE: The channel voltages should be between +3V and +40Vdc

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 theory of operation is essential for efficient troubleshooting. In figure 6.1, a portion of the measuring head is shown to illustrate the 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 difference between the bus field and the feedback field. The sensor output is amplified and is returned to the magnetic circuit in the form 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 amplifying section of the Signal converter 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 summed to 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 shunts to develop voltages for the meter and proportional outputs. The output current itself is also available at the output terminals, which are jumpered if not used.

6.3 SYSTEM DESCRIPTIONS

Effects of stray 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 assembly). A 4-channel system is used here as an illustration to simplify the drawing and explanation.

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 current feedback loop. The function of each current loop (current I

, I2, I3, or I4) is to maintain a state of zero flux in its related segment of the iron

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

, proportional to It. The common side of the shunt is returned to the four high-gain current

amplifiers.

Since the bus current is directly proportional to the total current I bus current can be measured accurately by summing the independent feedback currents (I

+ I2 + I3 + I4). Therefore, the bus current is equal to 5000It. Moving the measuring head

= I

with respect to the bus will cause the values of the individual feedback currents to change but will not affect the total current nor the accuracy of the measurement.

6.4 CIRCUIT FUNCTIONS

For the following discussion refer to the “High Range Module Schematic” and system schematic drawings as appropriate. These drawings are located in the back of the manual.

Figure 6.2

), develops an output voltage

by a ratio of 5000:1, the

Before discussing the various circuit functions, a general description of the metering unit will be helpful. A metering unit may consist of one or more modular units. Each modular unit contains the necessary circuitry for four channels of amplification. The metering unit also contains one main power transformer, circuit breaker, and the resistors or shunts to 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 trace the 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 called the control approximately 6 mAdc for each sensor. The control current is derived from the 12 Vdc power supply in the Signal converter. Since the sensor resistance is low (about 200 ohm), the sensor current is limited by two 1500-ohm resistors (one on each side of the sensor). These resistors are located in the measuring head.

With a constant dc control current applied to a sensor in the presence of a dc magnetic field, the sensor output is a dc voltage proportional to the dc field. The sensor output voltage is conducted via the interconnecting cable to the Signal converter, where it becomes the signal input.

current (Ic), 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 described in the remaining paragraphs.

6.6 POWER SUPPLIES

The LKP module contains a ±15 Vdc power supply, which powers only the on-board circuitry. The first module in the meter unit (also referred to as Module “1”) includes a 12 Vdc power supply for the Hall devices.

6.7 SYNC, PLL, AND RAMPS

The Signal converter employs phase locked loop circuitry for 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. It is then filtered and sent to U112 to be converted into a square wave, and then to the PLL circuitry. The output of the PLL is a square wave and is present at TP-2. This signal is sent to U104, U105, and RP101, which constitutes the ramp generator. The ramp generator output 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 for the SCRs.

6.8 ERROR AMPLIFIERS

The error amplifier circuitry consists of U106 through U109 and associated circuitry. The error amplifiers serve two purposes, to amplify 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 amplifiers to the two ramps generated by PLL and ramp generators. Two

Installation, Operation and Service Manual LKP Series

square waves are generated at the output of these comparators, one for the positive 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 cycle. Since these square waves are too long in duration, they cannot be used directly to drive the pulse transformer drivers. 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 channel #1) will be a pulse train which will be used to drive the pulse transformer drivers. Pulse train triggering is an advantage when noise on the line turns off an SCR. The SCR is retriggered 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 train 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 transformers (T203A and T203B for channel

1). The secondary of the pulse transformer develops a current pulse which drives the associated SCRs (SCR pack #1 for channel #1).

6.11 ACCURACY DIAGNOSTICS

“ACCURACY DIAGNOSTICS” (AD) is a system that assures the user that most internal circuits are operating properly and it is also a diagnostic tool. It is made up of a number of circuits, monitoring conditions of many of the critical components, circuits and connections within the current monitoring system. The AD subsystem provides relay contacts for the user to connect to his remote warning indicator. The AD diagnostic light emitting diodes on each meter unit module indicates proper operation of associated circuits. On some larger systems a red warning light mounted on the enclosure door provides a simple visual warning (refer to wiring diagram for this feature).

The AD indicates the feedback circuits are 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 polarity.

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 measurement systems, it is possible that 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 properly. This warning at low levels is most likely to occur if the metering system is associated with one of several rectifiers in the area.

Installation, Operation and Service Manual LKP Series

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 condition, it is an effective means of giving the user continual assurance of signal reliability.

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 errors. Consequently the metering system should not be in full, automatic control of the rectifier. The AD relay contact output is not intended to be the only monitor protecting the power rectifiers. Primarily, it is expected that the customer wants to take immediate action to prevent unsafe operation. Unsafe operation could result if the metering system is in the rectifier control loop and it erroneously produces a significantly lower output than is true. This might cause the rectifier control circuit to 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 potential problem, the 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:

A.) Line: This LED indicates whether the supply voltage to the meter unit falls within the

specified limit of +10%, -15% of nominal. Significant changes from these values will cause this LED to turn off and trip the relay.

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 connection between the cable and the metering unit or cable and measuring

head;

c. a bad Hall device in the head;

d. an open /or shorted coil in the head;

e. a primary current 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:

1.) Under certain conditions, external magnetic 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 (23Vdc is the minimum reliable channel voltage). This condition can cause false alarms. For more information on this, please refer to technical bulletin TEC9908, “Resolving External Magnetic Field Errors”.

Installation, Operation and Service Manual LKP Series

2.) In some installations, when the channel voltages are balanced, the channel LEDs

will remain on, even though the bus is turned down to zero. In this case, the accuracy diagnostics circuit is in an unstable condition and alarm faults, as indicated by the channel LEDs, should be ignored. Note that, in general, 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 remote warning system. The relay is closed under normal operating conditions and opens when a fault condition occurs. The output connections are available via Terminal Strip TS1 (see appropriate interconnection diagram for location).

Installation, Operation and Service Manual LKP Series

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 performed at the recommended interval to prevent or detect damage to the LKP system and to ensure continuing highaccuracy performance. 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.

IMPORTANT NOTE:

Keep organized, accurate recorded data (forms, etc.) from each Periodic Maintenance. This information may be invaluable in troubleshooting a malfunctioning LKP system.

7.2 ANNUAL MAINTENANCE

Perform the following steps at least once per year. If LKP system equipment is exposed to outdoor temperatures, DynAmp, LLC recommends these steps be performed during the hottest time of the year.

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

A.) Repeat voltage measurements given in "Magnetic Centering" procedure to ensure that

no significant change has occurred 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 proportionally, then that might indicate a change in the bus current. Remember that channel voltages will vary slightly depending on the ambient temperature of the head.

B.) Measure and record the Hall device dc power supply voltage.

C.) Visually inspect measuring head and interconnection cable for evidence of severe

overheating, excessive corrosion, or possible leaks in the RTV rubber seal around the aperture. Record any suspect conditions.

D.) Visually inspect Signal converter and signal converter(s) for evidence of severe

overheating, or excessive corrosion. Record any suspect conditions and take appropriate action.

E.) Clean the following items:

1.) Cables and external surfaces of measuring head and Signal converter:

2.) 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 cables or erase the silk-screening from the Signal converter.

Installation, Operation and Service Manual LKP Series

Signal converter interior (should only be performed after disconnecting power to the Signal converter): Dust and dirt can be removed by gently vacuum cleaning the unit. Be careful 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, which can be stripped away by certain solvents.

F.) Check the electrolytic filter capacitors for seals that have been popped (degassed), are

leaking electrolytic fluid or have excessive bulging. Contact DynAmp for repair options.

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

replaced according to the manufacturer instructions.

CAUTION

To avoid the risk of shock and electrocution, always disconnect the AC power and head cables from the head before performing any cleaning or service operation on the Signal converter.

Disconnect power to the system before servicing or replacing fuses.

7.3 CALIBRATION INTERVALS

DynAmp does not specify 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 17025:2005, 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.

7.4 SPARE PARTS ORDERS - ROUTINE OR EMERGENCY

Requests for spare parts should be directed to "Service" at DynAmp, LLC during normal hours. When contacting us, please present as much information as possible - the related equipment Model and Serial Numbers (available on the equipment tag); the required part

Installation, Operation and Service Manual LKP Series

name; its DynAmp, LLC item number (and other identifying or vendor number(s); and your time needs. An approved Purchase Order Number should be given with your order.

7.5 RECOMMENDED SPARE PARTS

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

TABLE 7.1

SPARE PARTS LIST*

DESCRIPTION ITEM NO. QTY

Signal converter

Kit, Spare Parts, LKP-8024 43808 1

Kit includes Module, Power supply, lamps & fuses as one package.

Module, LKP (4) channel electronics 41350 1

Power Supply 12V 19658 1

Bulb, “Fault” light 42405 1 Bulb, POWER ON light 26673 2 **Fuse, MDA1 Slo-blo (AC Primary) 12590 1 box

**Fuse, MDA3 Slo-blo (5 per box) Ch 1, 2, 3,4, 5, 6 12591 2 box PC Board Assembly, Accuracy Diagnostics 40355 1

PC Board Assembly, Accuracy Diagnostics, (2) channel 40402 1

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

(Head, cable, and Signal converter) should be kept on hand.

** All Fuses are Time lag MDA style (3AB) ¼” by 1 ¼” (6.3 mm x 32mm), 250 Volt

Disconnect power to the system before servicing or replacing fuses.

Installation, Operation and Service Manual LKP Series

7.6 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

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

8. RELATED TECHNICAL BULLETINS

The following is a list of available technical bulletins that contain relevant information in regards to high current measurements and the use of LKP systems. The technical bulletins are available upon request from DynAmp, LLC. Always consult the factory for a list of the latest technical bulletins.

TABLE 8.1

TECHNICAL BULLETINS LIST

Number Subject Title / Description

9908 External Fields Resolving External Magnetic Field Errors (replaces

TEC727)

9907 LKP/ LKB LKP and LKB Sensor Mounting Guidelines and

Restrictions

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

Current Systems

9904 Diagnostics Self Diagnostics for DynAmp High Current Measurement

systems (Accuracy Diagnostics)

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

Measurement Systems

749 Bus Analysis Computer Analysis of Measuring Head Locations In High

Current Measurement systems

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

Systems Heads on Busses

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

hours

941 Bus Analysis Data required for Bus Analysis of High Current

Measurement Systems

Installation, Operation and Service Manual LKP Series

This Page is Intentionally Blank

Installation, Operation and Service Manual LKP Series

9. DRAWINGS

TABLE 9.1

DRAWING LIST

DRAWING TITLE NUMBER

Schematic: LKP-8024 Power Input 05B108413

Schematic: LKP High Range Module 05B108074

Schematic: CM 4CH Alarm PC Board 05A107144

Schematic: CM 2CH Alarm PC Board 05A107147

Schematic: LKP-8024 Calibration Network 05B108412

Assembly: LKP-8024 Retrofit 84B108417

Assembly: Control PC Board 75A108104

Assembly: Supply & SCR Drive 75B108106

Assembly: Accuracy Diagnostics 07A109083

Assembly CM 4 Ch Alarm PC Board 26A107145

Assembly CM 2 Ch Alarm PC Board 26A107146

Interconnection: LKP-8024 Metering System 02B108418

Wiring Diagram: LKP Module 83C108030

Wiring Diagram: LKP-8024 83B108414

Wiring Diagram: LKP-8000 To FM Conversion - High Range 83B108232

Outline & Mounting, Module “1” 02D108221

Outline & Mounting, Module “2” 02D108222

DynAmp LKP-8024 Installation, Operation And Service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

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