DynAmp LKAT2 Setup guide

DynAmp, LLC
3735 Gantz Road Phone [phone] www.dynamp.com
Grove City, Ohio 43123 USA Fax [phone] [email protected]
LKAT2 4PC EMC
BI-DIRECTIONAL HIGH CURRENT
MEASUREMENT SYSTEM with RECTIFIER
PROTECTION FUNCTION
Installation, Operation and Service Manual
Manual Item No. 047314
Rev. A

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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.
Extended warranties may be available for purchase for some products. Extended warranties
are provided on a serial number by serial number basis as noted on DynAmp’s original
invoice and/or packing list.
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.
© 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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Table of Contents
Paragraph Title Page
DYNAMP, LLC WARRANTY ________________________________________________ iii
TABLE OF CONTENTS____________________________________________________ v
HAZARD WARNING!_____________________________________________________ vii
SAFETY ________________________________________________________________ ix
DYNAMP, LLC CUSTOMER SUPPORT & SERVICE ASSISTANCE_________________ xi
MANUAL REVISIONS ____________________________________________________ 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 MAINS POWER CABLE ASSEMBLY DETAIL ........................................................................ 8
2.6 SYSTEM OUTPUT CABLE ASSEMBLY DETAIL.................................................................... 8
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..................................................................................................................16
4.6 SYSTEM CHECKOUT........................................................................................................... 16
5. THEORY OF OPERATION ____________________________________________________21
5.1 GENERAL.............................................................................................................................21
5.2 OLOP TECHNOLOGY .......................................................................................................... 21
5.3 SYSTEM FUNCTIONAL DESCRIPTION............................................................................... 22
5.4 LKAT2METERING UNIT....................................................................................................... 23
5.5 LKAT2MEASURING HEAD INTERCHANGEABILITY........................................................... 23
5.6 TROUBLESHOOTING AN ACCURACY DIAGNOSTICS FAULT INDICATION..................... 23
5.7 SYSTEM CALIBRATION OVERVIEW................................................................................... 24
5.8 CALIBRATION ADJUSTMENTS ........................................................................................... 25
5.9 FIELD CONFIGURATION OF TRIP SETPOINTS ................................................................. 26
5.10 EARTH GROUNDING...........................................................................................................28
5.11 CONFIGURING THE LOW PASS FILTER............................................................................ 28
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
Figure 4.1 Installation Configuration with Mounting Angles........................................................16
Form 1 LKAT2Diagnostic Measurements Form 1– Zero Primary Current................................. 18
Form 2 LKAT2Diagnostic Measurements Form 2– Energized Primary Bus.............................. 19
Figure 5.1 Block Diagram of the LKAT2System........................................................................22
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 ....................................... 24
Table 5.2 Trip Configuration Details .........................................................................................27
Table 6.1 Spare Parts List........................................................................................................30
Table 7.1 Drawing List..............................................................................................................31

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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.
INSTALLATION
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.

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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
New
New Manual
07/18
27, 31
A
ECO #3351 – Regroup terms of equation for Table 5.2
for clarification.Remove drawing 02B109547C and
10/18
add 02B109566-.

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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
DynAmp’s new LKAT2 Portable is a lightweight, extremely rugged and easy to use AC / DC
measurement system for currents up to 150kA. Based on DynAmp’s well-proven 3rd
Generation OLOP technology, primary measurement accuracy is 0.25%.
The typical system is offered with a variety of Head ‘Sides’ enabling one system to measure
almost any current on a wide variety of bus bar sizes.
The LKAT2 is particularly well suited to measure power rectifier outputs for control and
protection purposes in electro-chemical processes such aluminum, chlorine, copper,
manganese, titanium, zinc, electroplating, etc.
KEY STANDARD FEATURES
System is compact, light-weight, rugged and easy-to-use.
Industry standard output signals for user instrumentation.
Optional second, fully isolated and independently scaled analog output signal. For example,
the main output can be scaled for 2kA with a ‘dead’ zone (0 amps = 0mA) while the second
analog output can be scaled for 100kA with a live zero for process control purposes (0 amps
= 4mA). Both measurement signals can be converted to voltage signals via plug on
adapters.
When assembled, Head Sides, interconnection cables and all Metering Unit connections are
IP65 rated.
STANDARD SYSTEM INCLUDES
4 or 6 Measuring Head Sides with connection cables (4 sides assemble into one complete
Measuring head).
Specially designed bus bar mounting brackets for temporary installation of Measuring Head
on both running/horizontal and vertical/rising bus bars.
Inter-connection cable (ITC) accepts 4 Head Side cables on one end, and connects to
Metering Unit on the other end.
LKAT
2
Head
LKAT2Metering Unit

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The LKAT2Metering Unit consists of a 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.
The Metering Unit features include:
•One analog output signal
•One configurable current level alarm with LED indication
•One Accuracy Diagnostics Alarm with LED indication
The system includes:
•Mains power adaptor with EU and US/Japan cords.
•Instrumentation signal output cable with banana jacks for connection to user’s
measurement instrumentation.
•Plug-on adaptors to convert mA measurement signal to a variety of voltage signals for
user’s instrumentation.
•1 year warranty
•Hard Side Carrying Case
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 the 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.

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•Custom Cable Lengths
Custom Measuring Head cable lengths can be provided but only at time of order. Note that
Measuring Head cable lengths can not be changed after order or in the field.
Custom Signal and Mains cables can be ordered. Note that optional Signal and Mains
cables can be shortened or replaced with longer cables in the field.
Custom ITC cables can be ordered.Note that ITC cables can be replaced with longer or
shorter cables in the field.
AVAILABLE ACCESSORIES
•Summing / Totalizing multiple LKAT systems
A dedicated external module is available for totalizing/summing up to 10 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 may be 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.
Each of the four head sides has a fixed cable coming from each elbow/corner with a circular
connector on the end. The primary four head sides are identified as A1, A2, B1 or B2.
These connect to the appropriate connector on one end of the ITC cable. The other end of
the ITC cable has two connectors labeled A and B which connect to connectors on the side
of the Metering Unit. 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.
Additional head sides are labeled C1, C2, D1, D2, etc.
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