DynAmp LKAT2 Manual

r
DynAmp
2
LKAT +24V
BI.DIRECTIONAL HIGH CURRENT
MEASUREMENT SYSTEM with RECTIFIER
PROTECTION FUNCTION
lnstallation, Operation and Service Manual
Manual ltem No. 046404
Rev. E
DynAmp, LLC

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DynAmp, LLC WARRANTY
Items and components manufactured by DynAmp, LLC for permanent installation are
warranted to be free from defects in material and workmanship for a period of two (2) years
from the date of shipment.
Items and components manufactured by DynAmp, LLC for portable and temporary use in
more than one location are warranted to be free from defects in material and workmanship for
a period of eighteen (18) months from the date of shipment.
Items and components not manufactured and resold by DynAmp, LLC are warranted by their
manufacturer.
Warranty repair shall be, at DynAmp’s option, in the form of repair or replacement of the
defective items or components. Concerning warranty repairs, DynAmp, LLC will be
responsible for DynAmp provided time, material and transportation costs (shipping or travel).
Actual method of warranty repair / correction will be determined by DynAmp, LLC at
DynAmp’s sole option. Such warranty repair shall constitute a fulfillment of all DynAmp, LLC
liabilities in respect to said items and components. In no event shall DynAmp, LLC be liable
for consequential damages.
Information in this document is subject to change without notice.
© 2014, 2016, 2017, 2018 DynAmp, LLC. All rights reserved.
Reproduction in any manner whatsoever for purposes other than installation, operation, or
service by the purchaser or end user without the written permission of DynAmp, LLC is strictly
forbidden.
This manual is part of the complete set of product documentation that includes installation,
operation, and service instructions, drawings and test results. Users should evaluate the
information in the context of the complete set of product documentation and their particular
applications. DynAmp, LLC assumes no liability for any incidental, indirect, or consequential
damages arising from the use of this documentation.
While all information presented is believed to be reliable and in accordance with accepted
engineering practices, DynAmp, LLC makes no warranties as to the completeness of the
information.
All trademarks used in association with LKAT2are trademarks of DynAmp, LLC.

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Hazard Warning!
Symbol
Identification:
General definitions of safety symbols used on equipment and manual.
Caution/Warning: Refer to accompanying documents for instructions.
GENERAL
All installation, maintenance and service must be performed by qualified
technicians who are familiar with the warnings and instructions of this manual.
Use of the equipment in a manner not specified by the manufacturer can impair
the protection provided within.
The enclosure cover must remain closed at all times during operation to ensure
safety of personnel. The cover may be opened using a screwdriver; however,
only authorized personnel or technicians should be allowed to open and service
the unit.
DynAmp, LLC does not assume liability for the customer’s failure to comply with
the rules and requirements provided in this manual.
HAZARDOUS
VOLTAGE
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.
This equipment is intended for indoor or outdoor use. It should be mounted in a
well-ventilated area, away from high heat, dust, and corrosive atmosphere. The
ambient temperature must not exceed specified limits.
For mounting considerations that fall outside the recommended specifications
provided in this manual, the factory should be contacted for approval.
This unit is rated for installation category II and pollution degree 2.
INSTALLATION

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SAFETY
The Measuring Head is designed to be installed on high voltage bus bars. All interconnection
cables must be safely routed away from bus bars and high voltages. Do not allow any
interconnection cable to contact bus bars or high voltages.
Ignoring the installation precautions and warnings can result in severe personal injury or
equipment damage. The following are general guidelines to be followed during installation,
operation and service of the Metering Unit and Measuring Head.
•All installation, maintenance and service must be performed by qualified technicians who
are familiar with the warnings and instructions of this manual.
•Always follow all local and plant safety procedures.
•The enclosure cover must remain closed at all times during operation to ensure safety of
personnel. Only authorized personnel or technicians should be allowed to open and
service the unit.
•Units are not intrinsically safe. Do not place in explosive atmospheres.
•Service must be performed by qualified technicians only. If use of an oscilloscope
becomes necessary during servicing, the scope must be floating and ungrounded or
differential probe(s) must be used. The Metering Unit is isolated from the mains via the
power transformers. If a grounded scope is used, a hazardous condition is created since
current will flow through the probe to ground.
•Use of the equipment in a manner not specified by the manufacturer can impair the
protection provided within.
•If a binding screw is used for the mains earth connection, the binding screw must be size
M4 (No. 6) or larger.
DynAmp, LLC does not assume liability for the customer’s failure to comply with the rules and
requirements provided in this manual.

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DynAmp, LLC Customer Support & Service Assistance
For further assistance, contact DynAmp Customer Support at:
Americas:
Telephone: [phone] Fax: [phone]
8:00 AM to 5:00 PM USA Eastern Time
From first Sunday in November to second Sunday in March – 13:00 GMT to 22:00 GMT
From second Sunday in March to first Sunday in November – 12:00 GMT to 21:00 GMT
After Hours Critical Service Emergency:
Telephone: [phone]
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:
[email protected]
DynAmp web:
www.dynamp.com

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MANUAL REVISIONS
Page
Change
Reason For Revision
Date
all
Rev NEW
06/14
all
A
CAR 10190 – Refine manual
08/14
17,18
B
ECR 2029 – Detail added to Form 1 & 2 showing pin
numbers
09/16
vi, v, 9,10,
14, 29,
30,31
C ECO 3337 – Delete fuse references, input power voltage,
Meter Unit item number, drawing list 01/17
ECR 2177 – Update drawing 75A109415 Rev A to B
10/17
5, 27,
31
D
ECO #3346 -Update MUT description, Non-Failsafe and
drawings
07/18
25, 31
E
ECR #2225 – Regroup terms of equation 5.2 for
clarification, remove drawing 75A109415B
09/18

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TABLE OF CONTENTS
Paragraph Title Page
DynAmp, LLC WARRANTY ________________________________________________ iii
Hazard Warning!_________________________________________________________ v
SAFETY _______________________________________________________________ vii
DynAmp, LLC Customer Support & Service Assistance ________________________ ix
MANUAL REVISIONS _____________________________________________________ xi
TABLE OF CONTENTS___________________________________________________ xiii
1. HANDLING AND STORAGE______________________________________________________1
2. PRODUCT DESCRIPTION _______________________________________________________3
2.1 SYSTEM OVERVIEW .............................................................................................................3
2.2 ADDITIONAL MEASURING HEAD DETAIL............................................................................ 6
2.3 ADDITIONAL METERING UNIT DETAIL................................................................................. 6
2.4 ADDITIONAL INDICATOR AND OUTPUT DETAIL................................................................. 7
2.5 INTERCONNECTION CABLE DETAIL.................................................................................... 7
3. SPECIFICATIONS______________________________________________________________9
4. INSTALLATION_______________________________________________________________13
4.1 HANDLING PRECAUTIONS................................................................................................. 13
4.2 INSTALLATION CONSIDERATIONS.................................................................................... 13
4.3 OFF-BUS FUNCTIONAL CHECK (Optional)......................................................................... 14
4.4 MEASURING HEAD INSTALLATION.................................................................................... 14
4.5 METERING UNIT INSTALLATION........................................................................................ 15
4.6 SYSTEM CHECKOUT........................................................................................................... 16
5. THEORY OF OPERATION ______________________________________________________19
5.1 GENERAL.............................................................................................................................19
5.2 OLOP TECHNOLOGY .......................................................................................................... 19
5.3 SYSTEM FUNCTIONAL DESCRIPTION............................................................................... 20
5.4 LKAT2METERING UNIT....................................................................................................... 21
5.5 LKAT2MEASURING HEAD INTERCHANGEABILITY........................................................... 21
5.6 TROUBLESHOOTING AN ACCURACY DIAGNOSTICS FAULT INDICATION..................... 21
5.7 SYSTEM CALIBRATION OVERVIEW................................................................................... 22
5.8 CALIBRATION ADJUSTMENTS ........................................................................................... 23
5.9 FIELD CONFIGURATION OF TRIP SETPOINTS ................................................................. 25
5.10 EARTH GROUNDING........................................................................................................... 26
5.11 CONFIGURING THE LOW PASS FILTER ........................................................................... 26
5.12 “FAILSAFE” / “NON-FAILSAFE” CONFIGURATION ............................................................ 27
6. MAINTENANCE & SPARE PARTS _______________________________________________29
6.1 PERIODIC MAINTENANCE.................................................................................................. 29
6.2 ANNUAL MAINTENANCE..................................................................................................... 29
6.3 SPARE PARTS.....................................................................................................................30
7. DRAWINGS__________________________________________________________________31

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FIGURES, FORMS & TABLES
Figure # Title ...........................................................................................................................Page
Figure 3.1 LKAT2Frequency Response ...................................................................................11
Form 1 LKAT2Diagnostic Measurements Form – Zero Primary Current................................... 17
Form 2 LKAT2Diagnostic Measurements Form – Energized Primary Bus................................ 18
Figure 5.1 Block Diagram of the LKAT2System........................................................................20
Table 2.1 Main and PE PC Board Assembly Features..............................................................7
Table 3.1 LKAT2 System Specifications ( subject to change without notice )............................ 9
Table 5.1 Troubleshooting an Accuracy Diagnostics Fault Indication ....................................... 22
Table 5.2 Trip Configuration Details .........................................................................................25
Table 5.3 Low Pass Filter Switch Settings................................................................................ 26
Table 5.4 LKAT2 Alarm Relay Status ........................................................................................27
Table 6.1 Spare Parts List........................................................................................................30
Table 7.1 Drawing List..............................................................................................................31

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1. 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°C to 70°C
-40°F to 158°F
Storage Humidity: Maximum 85%, non-condensing
DynAmp, LLC does not assume liability for the customer’s failure to comply with handling and
storage requirements.
For further assistance, contact DynAmp customer support.

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2. PRODUCT DESCRIPTION
2.1 SYSTEM OVERVIEW
The LKAT2combines accurate high current measurement with reverse and overcurrent
protection in a single rugged and cost effective system.
The next generation of DynAmp’s well proven OLOPTM technology, LKAT2offers a new level
of accuracy and stability to accurately and reliably measure uni- and bi-directional DC as well
as AC bus currents.
The LKAT2is particularly well suited to measure power rectifier outputs for control and
protection purposes in electro-chemical processes such aluminum, chlorine, copper,
manganese, titanium, zinc, electroplating, etc.
LKAT2 Metering Unit
KEY STANDARD FEATURES
True bi-directional performance. Ideal for difficult magnetic applications. No head position or
bus analysis needed.
Extremely compact with excellent environmental specifications for installation flexibility, inside
or outside.
Multiple, standard switch selectable measurement output signals including mA, mV and V.
Standard Accuracy Diagnostics “AD” continuously monitors system performance providing
both local LED and relay contact output.Optional LKAT2Protection Extensions, (PE),
provides additional functionality for protecting high current rectifiers.
Standard Alarm provides reverse or over-current protection via an LED viewable at the
metering electronics and a dry contact relay output.
The LKAT2Metering Unit consists of a +24V power supply and Main pc board mounted
together on a steel U-chassis. Input, output, and power connections are made via pc board
edge connector plugs.
LKAT2Measuring Head

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Each standard LKAT2is delivered with the following
•A new, ruggedized two-piece Measuring Head with integrated mounting hardware and bus
bar corner (fiberglass angles). Each head half has its own cable for connection to the
metering electronics.
•Very compact Metering Electronics with one analog measurement output, one Accuracy
Diagnostics system status output and one configurable Alarm output for overcurrent or
reverse current protection.
•System output cable
•Power input cable
•Comprehensive User’s Manual
•Factory calibration data and graphs
•2-year warranty for permanent installed systems
•Packaging suitable for air /ground transport
AVAILABLE OPTIONS
•Protection Extensions ( PE )
The PE option adds additional functionality for protecting high current rectifiers. This option is
either factory configured with a new system or can be added to LKAT2Systems already in the
field. If added in the field, some field configuration may be required.
Second Freely Scalable Analog Output :
This second analog output is independently scaled and fully isolated from the standard LKAT2
measurement output. In typical applications, it is scaled to provide accurate measurement
above the standard rectifier operating range for advanced protection purposes. For example,
the primary LKAT2output may be scaled to 50kA to provide the highest degree of accuracy
and resolution for normal rectifier control. The second PE output may be scaled to 75kA to
provide the information to intelligently manage overcurrent situations. Using this signal, the
rectifier control system could integrate overcurrent operation to allow 5 minutes at 110%, 1
minute at 120%, 10 sec at 140%.
Two Additional Protection Relays :
These relays bring total number of configurable relays to three. Each can be configured to
provide reverse or various degrees of overcurrent protection. Like the standard alarm, these
two additional PE alarms come with their own, independent local LED indication and relay
outputs.
•Digital current display ( 3 1/2 digit )
This option is mounted behind the clear front door of the metering electronics enclosure to
display either DC or RMS AC bus current locally.Please note that this option reduces the
maximum metering electronics ambient temperature to 50ºC. This option can also be added
to LKAT2Systems already in the field.
•Custom Cable Lengths
Custom Measuring Head cable lengths can be provided but only at time of order. Note that
Measuring Head cable lengths cannot be changed after order or in the field because one end
is terminated inside the Measuring Head and the other end is terminated inside a fixed
connector.
Custom Signal and Mains cable lengths can be provided. Note that standard Signal and
Mains cables can be shortened or replaced with longer cables in the field.

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AVAILABLE ACCESSORIES
•Summing / Totalizing multiple LKAT systems
A dedicated external module is available for totalizing/ summing LKAT measurement signals.
This is typically used to provide a true ‘total’ current signal when multiple rectifiers ( with
individual LKAT systems ) are connected in parallel to provide a higher total current.
.
•LKAT Metering Unit Tester ( LKAT MUT )
The LKAT MUT is a portable tester used to verify the functionality of Metering Units for all
versions of the LKAT family of products.
Adapters included with the LKAT MUT allow the tester to be connected directly and check any
LKAT Metering Unit electronics.
The functions and parameters checked by the LKAT MUT include:
•Input / output sensitivity
•Trip point scaling
•Trip relay contacts
•Integrity of input / output harnesses and interconnections on Metering Unit
The tools / documentation required to use the LKAT Metering Unit Tester include :
•4-1/2 digit DMM with 0.05% basic DC accuracy ( user provided )
•DMM Test probes ( user provided )
•Banana to banana cables ( 1black / 1 red )
•LKAT MUT Product Manual
More information on the LKAT MUT can be found at www.dynamp.com or by contacting
DynAmp.

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•Extended Warranty
For permanently installed systems, the standard 2-year warranty can be extended in 2-year
increments. This must be ordered less than 6 months after the original LKAT system is
shipped.
2.2 ADDITIONAL MEASURING HEAD DETAIL
LKAT2 Measuring Heads contain an arrangement of Hall Effect sensor ICs and signal
conditioning electronics. The tubular enclosure is constructed of flame retardant plastic with
an internal aluminum frame. Insulation from the bus is provided by the homogeneous
(sealed) construction of the head. In the event that the head enclosure components become
cracked, the bonding fails, or the weather-tight seal is broken in any way, a replacement head
must be substituted. The Measuring Head is not designed to be repaired.
LKAT2Measuring Heads are mounted on the bus bar using fiberglass angles positioned on
the corners of the bus bar and stainless steel bus bar mounting screws threaded into the
Measuring Head structure. Mounting hardware is supplied with each system. These screws
are adjusted to bus dimensions specified with each order. When properly installed, the
mounting hardware maintains the position of the Measuring Head in the event of temperature
fluctuation and / or bus vibration.
An interconnection cable assembly is integral to each half of the Measuring Head. Measuring
Heads with extra-long interconnection cables are also available - consult the factory for
details. Standard Measuring Head cable assemblies are terminated with keyed connectors to
ensure correct hookup. The interconnection cables from the Measuring Head are identified
as “A” and “B”. Connecting head cable “A” to Metering Unit “B” will not result in damage to
the head or electronics, but may degrade the calibration accuracy of the system.
2.3 ADDITIONAL METERING UNIT DETAIL
The Metering Unit electronics are housed in an environmentally rugged enclosure. The
enclosure cover must remain closed during normal operation.
The outside of the Metering Unit enclosure includes four receptacles for external connection
to the Measuring Head, the Metering Unit measurement signal(s) and relay outputs, and the
input of mains power. When properly mated with the associated cable assembly, these
connections are also environmentally protected.
Internally, all LKAT2Metering Units include both a Power Supply pc board and a Main pc
board. These 2 PC boards are mounted to a steel chassis which is then mounted on a steel
panel housed in the enclosure. The Metering Unit enclosure door has a window made of
clear polycarbonate. This allows the user to view various LED (or LCD) status indicators
while the door is closed. For more information, refer to the “Theory of Operation” section of
this manual.
There are two optional pc board assemblies that may be added onto the Main pc board in the
LKAT2Metering Unit:
•The Protection Extensions ( PE ) pc board assembly
•The Display pc board assembly.
One or both of these pc board assemblies may be added to an LKAT2 Metering Unit in the
field. It is not mandatory that they be factory installed and/or calibrated. The optional pc
board assemblies may be calibrated on site, using the LKAT2 Main Output as the reference
measurement.