DynAmp LKP-180 Manual

DynAmp, LLC
3735 Gantz Road Phone [phone] www.dynamp.com
Grove City, Ohio 43123 USA Fax [phone] [email protected]
MODEL LKP-180, LKP-300, & LKP-400
DIRECT CURRENT METERING SYSTEMS
Installation, Operation and Service Instructions
Manual Item No. 041749
Rev. K

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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.
© 1997, 1998, 1999, 2000, 2002, 2003, 2004, 2006, 2008, 2011, 2016 DynAmp, LLC. All rights reserved.
Reproduction for purposes other than operation and service without written permission of DynAmp, LLC is
strictly forbidden.
This manual includes detailed drawings, installation, operation, service and maintenance. Users should
evaluate the information in the manual and their particular application. DynAmp assumes no liability for any
incidental, indirect, or consequential damages arising fro the use of this documentation.
While all information presented is believed to be reliable and in accordance with accepted engineering
practices, DynAmp makes no warranties as to the completeness of the information.

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Hazard Warning!
Symbol Identification:
General definitions of safety symbols used on equipment and manual.
Caution/Warning: Refer to accompanying documents for instructions.
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 are provided for locking the doors. Only
authorized personnel or technicians should be allowed to open and service the
unit.
Disconnect power to the system before servicing or 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.
GENERAL
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 use only. It should be mounted in a well-
ventilated area, away from high heat, dust, and corrosive atmosphere. The
ambient temperature must not exceed 55°C.
For mounting considerations that fall outside the recommended specifications
provided in this manual, the factory should be contacted for approval.
This unit is rated for installation category III and pollution degree 2.

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DynAmp, LLC Customer Support
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
Europe:
Telephone: [phone] Fax: [phone]
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: [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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REVISION PAGE
Page
Change
Reason For Revision
Date
all
Rev NEW
9/97
all
Rev A
Added LKP-400 information, updated LKP-180 & 300
Drawings
7/98
all
Rev B
Updated mounting instructions, accuracy diagnostics
information, and wiring diagrams.
8/99
i,
Rev C
Warranty, Installation Considerations
03/00
i,7,34
Rev D
Warranty & paragraph in Installation for OP’s check,
Spare Parts
08/00
27, 34
Rev E
Updated Accuracy Diagnostics, Spare Parts sections
02/02
iii, 7
Rev F
Updated Warranty and Installation paragraph
10/03
all
Rev G
Update to DynAmp, LLC
12/04
v, 1, 32,
34
Rev H
Update fuse precautions per ECR 1304
07/06
39
Rev I
ECO 3166 update accuracy diagnostics drawings/list
09/08
all Rev J
PAR 10245 – Handling & Storage, ECR 1440- Calibration
Intervals / New Manual Format 06/11
1,2,11,19 Rev K ECO 3307 – Section 1 Safety, Installation Precautions,
Metering Unit Wiring 10/16

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TABLE OF CONTENTS
Paragraph Title Page
1. SAFETY ____________________________________________________________ 1
2. HANDLING AND STORAGE ____________________________________________ 3
3. DESCRIPTION _______________________________________________________ 5
3.1 OVERVIEW..........................................................................................................................5
3.2 MEASURING HEAD .............................................................................................................5
3.3 METERING UNIT..................................................................................................................5
3.4 CABLE..................................................................................................................................5
3.5 ELECTRICAL .......................................................................................................................6
4. SPECIFICATIONS ____________________________________________________ 7
5. INSTALLATION ______________________________________________________ 9
5.1 HANDLING PRECAUTIONS.................................................................................................9
5.2 INSTALLATION CONSIDERATIONS ...................................................................................9
5.3 INSTALLATION PRECAUTIONS (LIVE BUS).....................................................................11
5.4 MAGNETIC CONSIDERATIONS: MEASURING HEAD ......................................................12
5.5 HEAD INSTALLATION .......................................................................................................13
5.6 COMPLETING THE HEAD INSTALLATION .......................................................................15
5.7 METERING UNIT INSTALLATION......................................................................................18
5.8 METERING UNIT WIRING .................................................................................................19
5.9 INITIAL SYSTEM CHECKOUT ...........................................................................................19
5.10 MAGNETIC CENTERING...................................................................................................21
6. THEORY OF OPERATION _____________________________________________ 25
6.1 GENERAL ..........................................................................................................................25
6.2 MAGNETIC SENSOR (NULL DETECTOR) ........................................................................25
6.3 SYSTEM DESCRIPTIONS .................................................................................................25
6.4 CIRCUIT FUNCTIONS .......................................................................................................26
6.5 METERING UNIT................................................................................................................27
6.6 POWER SUPPLIES............................................................................................................27
6.7 SYNC, PLL, AND RAMPS...................................................................................................27
6.8 ERROR AMPLIFIERS.........................................................................................................27
6.9 COMPARATORS AND PULSE GENERATOR....................................................................28
6.10 PULSE TRANSFORMER DRIVERS...................................................................................28
6.11. OUTPUT CIRCUIT .............................................................................................................28
6.12 ACCURACY DIAGNOSTICS (OPTIONAL) ........................................................................29
7. MAINTENANCE & SPARE PARTS ______________________________________ 31
7.1 PERIODIC MAINTENANCE................................................................................................31
7.2 ANNUAL MAINTENANCE...................................................................................................31
7.3 CALIBRATION INTERVALS...............................................................................................32
7.4 SPARE PARTS ORDERS -ROUTINE OR EMERGENCY...................................................33
7.5 RECOMMENDED SPARE PARTS......................................................................................33

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7.6 SERVICE ASSISTANCE.....................................................................................................35
8. RELATED TECHNICAL BULLETINS_____________________________________ 37
9. DRAWINGS ________________________________________________________ 39
DRAWINGS & TABLES
Figure # Title Page
Figure 5.1 Measuring Head Sectional Layout..........................................................................9
Figure 5.2 General Guidelines for Locating Measuring Heads ...............................................13
Figure 5.3. Setting The Lower Head Half Upright...................................................................14
Figure 5.4 Setting The Upper Head Half On The Lower Half..................................................15
Figure 6.1 Magnetic Null Detector Diagram............................................................................25
Figure 6.2 Functional Diagram of Four-Channel System....................................................26
Table 4.1 LKP Series 16 Channel Specifications ................................................................7
Table 4.1 LKP Series 16 Channel Specifications, Continued ..............................................8
Table 4.2 Typical Error At Zero Bus Current*......................................................................8
Table 5.1 Measuring Head Resistance Chart........................................................................17
Table 5.1 Measuring Head Resistance Chart (Continued).....................................................18
Table 5.2 Calculated Channel Voltage..................................................................................20
Table 5.3 Form for Recording Channel Voltage Measurements............................................23
Table 7.1 Spare Parts List* .................................................................................................33
Table 7.1 Spare Parts List* continued.................................................................................34
Table 8.1 Technical Bulletin List............................................................................................37
Table 9.1 Drawing List..........................................................................................................39

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1. SAFETY
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 is heavy and requires 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 Metering 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.
•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 Metering Unit is isolated from the mains via the power transformers. If a grounded
scope is used, a hazardous condition is created since current will flow through the
probe to ground.
•Units are not intrinsically safe. Do not place in explosive atmospheres
•Do not place in the rain, or under water, or submerge any part of the Measuring Head
or Metering Unit. The Measuring Heads are splash proof but are not waterproof.
•The surface on which the Measuring Head is mounted must be sound and capable of
supporting the head. Fasteners used must be capable of supporting the weight of the
head.
•Make sure that the cables are disconnected from the head during installation.
•The Measuring Heads are supplied with connector covers, which must be used
whenever the head cables are disconnected from the head. The covers are necessary
to prevent dust and water from entering the Measuring Heads. The covers also prevent
fingers from contacting the connector pins during installation, which can carry
hazardous voltages if the head is installed on a live bus.
•If the installation is to be made on a "live" bus, the Measuring Head cables 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. Personal protective gear
should be worn when reconnecting cable back to Measuring Head. Please refer to
installation section for head storage on a live bus.
•Measuring Head should be electrically isolated from the bus bars. A ¼” (6mm)
minimum distance between the bus and window insulation should be maintained. This
will insure electrical isolation of the head structure from the bus. The head itself is
grounded via the cables to the Metering Unit. Refer to the “Installation Consideration”
section of the manual for more details.
•An external circuit breaker or fuse with proper rating is required for branch circuit
protection when wiring the main circuit to this Metering Unit. Each Metering Unit must
have its own breaker. Use a wire and breaker or fuse (time-delay) sized adequately for
the maximum burden of 20 VA/kA of measured current. The wire should have an
insulation rating of 600Vac and 80°C minimum temperature rating.

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•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.
•Metering Unit covers must be present or, when equipped, enclosure doors must remain
closed at all times during operation to insure safety of personnel. A set of keys is
provided for locking enclosure doors. Only authorized personnel or technicians should
be permitted to open and service the unit.
•Bus current must be zero when taking resistance measurements.
•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.

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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 OVERVIEW
The DynAmp, LLC LKP Series 16 Channel are systems for accurately measuring direct
current in a bus. The Models in this series are: LKP-180, LKP-300 and LKP-400. Each
model consists of a Measuring Head, a Metering Unit, and multi-conductor cables.
3.2 MEASURING HEAD
A magnetic core encircles the bus passing through the center of the Measuring Head.
Magnetic null detectors are mounted in air gaps in the core. Each null detector is flanked
by coils located on the magnetic core.
The Measuring Heads are constructed of cast aluminum with a tough powder coating
finish, insulation from the bus being provided by a 3/8 in. (9.5mm) layer of high-grade
polymer.
The LKP 16 channel Measuring Heads are provided with mounting feet as standard
equipment. The mounting feet facilitate the mounting of the heads vertically on the floor or
on a platform.
3.3 METERING UNIT
The Metering Unit is housed in a standard NEMA type enclosure (An IP54 upgrade is
available). In addition to the electronic circuitry (housed within four modular units), the
Metering Unit contains terminals for all external connections. The Metering Unit requires
120/240 Vac (other voltages available), 50 or 60 Hz power. Burden on the supply circuit
will not exceed 8000VA (LKP-400) under normal operating conditions (about 20VA/kA). A
thermo-magnetic circuit breaker is mounted on the inside of the enclosure and serves as
the power on-off control.
3.4 CABLE
Standard interconnecting cables are supplied with each system such that the distance
between the cabinet and the head is approximately 33 feet (10 meters), without regard to
which side of the head the Metering Unit is installed (longer cable lengths are available -
consult the factory for details). Each of the individual conductors is tagged with a
numbered label corresponding to a terminal block connection, providing an easy hookup to
the Metering Unit. Keyed connectors are provided on the Measuring Head side of the
cables to ensure correct hookup.

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3.5 ELECTRICAL
Six outputs are provided by the system:
1. A standard voltage output of 1 mV/kA.
2. An optional secondary voltage output (scaled per customer order - typically 1V @ FS).
3. A current output of 1 Adc per 5 kA of bus current.
4. A normally open (N.O.) contact for the Metering Unit over-temperature alarm, rated at
120 Vac, 6 A.
5. A normally closed relay contact for accuracy diagnostics output. This feature is only
available when the accuracy diagnostics option is ordered.
6. Optional isolated shunt output. Scaling is per customer order: 0-10V, 4-20mA
available.

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4. SPECIFICATIONS
TABLE 4.1
LKP SERIES 16 CHANNEL SPECIFICATIONS
MODEL
MAX. FULL-
SCALE RANGE*
MEASURING HEAD
WEIGHT
METERING UNIT WEIGHT
(Maximum)
LKP-180
180 kA
Approx. 1488 lb. (675 kg)
Approx. 650 lb. (295 kg)
LKP-300 300 kA Approx. 2468 lb. (1120 kg) Approx. 800 lb. (363 kg)
LKP-400
400 kA
Approx. 3968 lb. (1800 kg)
Approx. 800 lb. (363 kg)
Ambient Temperature Range of Measuring
Head
-20°C to 55°C
Ambient Temperature Range of Metering Unit
Location
-20°C to 55°C
Humidity (head and Metering Unit) 85% maximum (non condensing)
AC Line Voltage at 50 or 60 Hz ±5Hz**
100,120,200,220,240 Vac +10%, -15%
Burden on ac Line*** 20 VA/kA
Maximum Allowable Burden of Output Circuit
15 volts
Linearity Error±0.03% of full scale from 5% to 100% of bus
current.
Repeatability Error Limits±0.02% of full scale plus zero error. 
Temperature Sensitivity ±0.002%/°C
Line Voltage Sensitivity ±0.001%/V @ 120V ac
±0.0005%/V @ 240V ac
Measuring Head To Bus Isolation 12kVac for 1 minute with 25mm air gap. See
notes below.
Installation Category III
Pollution Degree
2
* Contingent upon DynAmp, LLC computer analysis of bus system.
** 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.
*** Size any external isolation transformers for 30VA/kA to avoid overheating the transformers due to the
presence of SCR generated harmonics on the input ac line.
When tested at 120 Vac, less than 1 V burden, 24°C ambient.
 Typical zero primary current errors (bus equiv.) for each model are shown in table 4.2.
 With bus passing through window insulation at 90° to the head.

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TABLE 4.1
LKP SERIES 16 CHANNEL SPECIFICATIONS, CONTINUED
OUTPUTS
Current output:
1 A/5 kA, ±0.1% full scale
Voltage output, ALL
1mV per kA of bus current, ±0.1% full scale
PHYSICAL
Overall Dimensions, in. (mm):
LKP Metering Unit (all)
66 (1676)H x 48 (1220)Wx 16 (406)D
LKP-180 Measuring Head (Version 1)
78.3 (1989)H x 111.1 (2823)W x 25.2 (640)D
LKP-180 Measuring Head (Version 2)
102.2 (2597)H x 101.3 (2572)W x 25.2 (640)D
LKP-300 Measuring Head (Version 1)
97.4 (2473)H x 142.8 (3627)W x 25.2 (640)D
LKP-300 Measuring Head (Version 2)
130.4 (3310)H x 129.1 (3280)W x 25.2 (640)D
LKP-400 Measuring Head (Version 1)
118 (2999)Hx 169.7 (4310)Wx 31.9 (810)D
LKP-400 Measuring Head (Version 2)
156.2 (3967)Hx 153.87 (3908)Wx 31.9 (810)D
Max. Aperture Dimensions in. (mm):
LKP-180 Measuring Head (Version 1)
59.4 (1508) Hx 93.2 (2368)W
LKP-180 Measuring Head (Version 2)
83.8 (2116) Hx 83.3 (2116)W
LKP-300 Measuring Head (Version 1)
76.4 (1939) Hx 123 (3123)W
LKP-300 Measuring Head (Version 2)
108.7 (2760) Hx 108.7 (2760)W
LKP-400 Measuring Head (Version 1)
92.9 (2360) Hx 146.8 (3730)W
LKP-400 Measuring Head (Version 2)
131 (3328) Hx 131 (3328)W
NOTE
The Measuring Head window insulation rating is directly proportional to the clearance of the
head to the bus. For instance, a bus in direct contact with the window insulation of the head will
have an insulation rating of 6kV. A clearance of 1" increases the window insulation rating to 12
kV. Thus, the greater the distance through the air between the bus and the head, the greater
the insulation rating will be.
TABLE 4.2
TYPICAL ERROR AT ZERO BUS CURRENT*
Models
Max. Core Set
LKP-180
±27 amperes
LKP-300
±45 amperes
LKP-400
±60 amperes
* Excluding effects of external buses. See section concerning the magnetic effects of external
buses.