DynAmp LKP-8024 Manual
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
Installation, Operation and Service Manual LKP Series
This Page is Intentionally Blank
© 2011 DynAmp, LLC Page ii
041837 H
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.
© 1999, 2000, 2001, 2002, 2004, 2005, 2008, 2011 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.
© 2011 DynAmp, LLC Page iii
041837 H
Installation, Operation and Service Manual LKP Series
This Page is Intentionally Blank
© 2011 DynAmp, LLC Page iv
041837 H
Installation, Operation and Service Manual LKP Series
Hazard Warning!
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
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.
GENERAL
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.
HAZARDOUS
VOLTAGE
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 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.
INSTALLATION
Symbol
Identification:
General definitions of safety symbols used on equipment and manual
Caution/Warning: Refer to accompanying documents for instructions.
© 2011 DynAmp, LLC Page v
041837 H
Installation, Operation and Service Manual LKP Series
This Page is Intentionally Blank
© 2011 DynAmp, LLC Page vi
041837 H
Installation, Operation and Service Manual LKP Series
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:
DynAmp web:
www.dynamp.com
© 2011 DynAmp, LLC Page vii
041837 H
Installation, Operation and Service Manual LKP Series
This Page is Intentionally Blank
© 2011 DynAmp, LLC Page viii
041837 H
Installation, Operation and Service Manual LKP Series
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
12/00
19 B Deleted text regarding Hall Sensor power supply.
3/01
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.)
11/05
v, 1, 22,
24
Rev F Update fuse precautions per ECR 1304 07/06
29 G ECO 3166 update accuracy diagnostics drawings/list 09/08
all H PAR 10245 – Handling & Storage, ECR 1440- Calibration
Intervals / New Manual Format
06/11
© 2011 DynAmp, LLC Page ix
041837 H
Installation, Operation and Service Manual LKP Series
This Page is Intentionally Blank
© 2011 DynAmp, LLC Page x
041837 H
Installation, Operation and Service Manual LKP Series
TABLE OF CONTENTS
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
© 2011 DynAmp, LLC Page xi
041837 H
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 # Title ................................................................................................. Page
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
© 2011 DynAmp, LLC Page xii
041837 H
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.
•
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.
•
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.
© 2011 DynAmp, LLC Page 1
041837 H
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.
© 2011 DynAmp, LLC Page 2
041837 H
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.
© 2011 DynAmp, LLC Page 3
041837 H
Installation, Operation and Service Manual LKP Series
This Page is Intentionally Blank
© 2011 DynAmp, LLC Page 4
041837 H
Installation, Operation and Service Manual LKP Series
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 open the current loop while
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.
© 2011 DynAmp, LLC Page 5
041837 H
Installation, Operation and Service Manual LKP Series
This Page is Intentionally Blank
© 2011 DynAmp, LLC Page 6
041837 H
Installation, Operation and Service Manual LKP Series
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.
© 2011 DynAmp, LLC Page 7
041837 H
Installation, Operation and Service Manual LKP Series
This Page is Intentionally Blank
© 2011 DynAmp, LLC Page 8
041837 H
Table of contents
Other DynAmp Measuring Instrument manuals
