Dynamp Lkp series Setup guide

DynAmp, LLC

3735 Gantz Road Phone +1 614.871.6900 www.dynamp.com

Grove City, Ohio 43123 USA Fax +1 614.871.6910 [email protected]

Model LKP-45, LKP-60, & LKP-80

DIRECT CURRENT METERING SYSTEMS

Installation, Operation and Service Manual

Manual Item No. 041736

Rev. N

Installation, Operation and Service Manual LKP Series

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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.

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 application. 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 LKP are trademarks of DynAmp, LLC.

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The LKP Series 10 Channel includes the LKP-100 Metering Unit. This Metering Unit

conforms to the latest European directives and standards concerning safety and

electromagnetic compatibility.

Application of Council Directive(s):

73/23/EEC, 89/336/EEC and 93/68/EEC.

Standards to which conformity is declared:

•EN50081-2 utilizing method EN55011: Radiated and Conducted Emissions for Heavy

Industrial Environments, Class A.

•EN50082-2: Radiated and Conducted Immunity Tests for Heavy Industrial

Environments.

Safety Standards:

•EN 61010-1: Safety Requirements for Electrical Equipment for Measurement, Control,

and Laboratory Use.

Note

According to EN 50082, the manufacturer must state the degradation of performance level acceptable during

immunity tests. Unless otherwise noted in the manual or data sheet, DynAmp limits degradation during

immunity tests for this equipment to < 0.5% FS for A-criterion tests.

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TABLE OF CONTENTS

Paragraph Title Page

DYNAMP, LLC WARRANTY_____________________________________________________III

TABLE OF CONTENTS________________________________________________________ VII

HAZARD WARNING!__________________________________________________________ IX

SAFETY ____________________________________________________________________ XI

DYNAMP, LLC CUSTOMER SUPPORT & SERVICE ASSISTANCE____________________ XIII

MANUAL REVISIONS ________________________________________________________XV

1. HANDLING AND STORAGE................................................................................................1

2. PRODUCT DESCRIPTION...................................................................................................3

2.1 SYSTEM OVERVIEW _________________________________________________ 3

2.2 ADDITIONAL MEASURING HEAD DETAIL ________________________________ 3

2.3 ADDITIONAL METERING UNIT DETAIL___________________________________ 3

2.4 INTERCONNECTION CABLE DETAIL ____________________________________ 3

2.5 ELECTRICAL________________________________________________________ 4

3. SPECIFICATIONS................................................................................................................5

4. INSTALLATION....................................................................................................................7

4.1 HANDLING PRECAUTIONS ____________________________________________ 7

4.2 MAGNETIC CONSIDERATIONS: MEASURING HEAD _______________________ 7

4.3 MEASURING HEAD INSTALLATION _____________________________________ 8

4.4 INSTALLATION CONSIDERATIONS ____________________________________ 10

4.5 INSTALLATION PRECAUTIONS (LIVE BUS)______________________________ 12

4.6 COMPLETING THE MEASURING HEAD INSTALLATION____________________ 12

4.7 METERING UNIT INSTALLATION ______________________________________ 16

4.8 METERING UNIT WIRING ____________________________________________ 17

4.9 INITIAL SYSTEM CHECKOUT _________________________________________ 17

4.10 MAGNETIC CENTERING _____________________________________________ 18

4.11 REVERSING CABLE EXIT DIRECTION ON MEASURING HEAD ______________ 20

5. THEORY OF OPERATION.................................................................................................23

5.1 GENERAL _________________________________________________________ 23

5.2 MAGNETIC SENSOR (NULL DETECTOR)________________________________ 23

5.3 SYSTEM DESCRIPTIONS_____________________________________________ 23

5.4 CIRCUIT FUNCTIONS________________________________________________ 24

5.5 METERING UNIT____________________________________________________ 25

5.6 POWER SUPPLIES__________________________________________________ 25

5.7 SYNC, PLL, AND RAMPS _____________________________________________ 25

5.8 ERROR AMPLIFIERS ________________________________________________ 25

5.9 COMPARATORS AND PULSE GENERATOR _____________________________ 25

5.10 PULSE TRANSFORMER DRIVERS _____________________________________ 26

5.11 OUTPUT CIRCUIT___________________________________________________ 26

5.12 ACCURACY DIAGNOSTICS (OPTIONAL)________________________________ 26

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6. MAINTENANCE & SPARE PARTS ....................................................................................29

6.1 PERIODIC MAINTENANCE____________________________________________ 29

6.2 ANNUAL MAINTENANCE _____________________________________________ 29

6.3 RECOMMENDED CALIBRATION VERIFICATION INTERVALS _______________ 30

6.4 SPARE PARTS ORDERS - ROUTINE OR EMERGENCY ____________________ 31

6.5 RECOMMENDED SPARE PARTS ______________________________________ 31

7. RELATED TECHNICAL BULLETINS.................................................................................33

8. DRAWINGS........................................................................................................................35

FIGURES & TABLES_____________________________________________________________

Figure # Title...................................................................................................................Page

Figure 4.1 General Guidelines for Locating Measuring Heads .....................................................8

Figure 4.2 Window Insulation Nomenclature Typical For LKP Series Measuring Heads .............9

Figure 4.3 Proper Lifting Technique...........................................................................................12

Figure 5.1 Magnetic Null Detector Diagram................................................................................23

Figure 5.2 Functional Diagram of Four-Channel System............................................................24

Table 3.1 LKP Series 6 & 8 Channel Specifications....................................................................5

Table 3.2 Typical Error At Zero Bus Current*..............................................................................6

Table 4.1 (A) Measuring Head Resistance Chart LKP-45 ........................................................14

Table 4.1 (B) Measuring Head Resistance Chart LKP-60 ........................................................15

Table 4.2 Measuring Head Resistance Chart LKP-80...............................................................16

Table 4.3 Channel Voltage Measurements Form: LKP-45 & LKP-60 ........................................21

Table 4.4 Channel Voltage Measurements Form: LKP-80 ........................................................22

Table 6.1 Spare Parts List* .......................................................................................................32

Table 7.1 Technical Bulletin List................................................................................................33

Table 8.1 Drawing List...............................................................................................................35

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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.

The CE mark proves the compliance of the equipment with the requirements

of the directives.

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, LLC 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 the 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 III and pollution degree 2.

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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 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.

•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 Measuring Head. Fasteners used must be capable of supporting

the weight of the Measuring Head.

•Make sure that the cables are disconnected from the Measuring Head during

installation.

•The Measuring Heads are supplied with connector covers, which must be used

whenever the Measuring Head cables are disconnected from the Measuring 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 Measuring 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 Measuring Head. A condition hazardous to the Measuring

Head and any person handling un-insulated cable-lead terminals will result if metal

parts of the Measuring 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 Considerations” section 4.4 for

Measuring 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 Measuring Head structure from the bus.

The Measuring Head itself is grounded via the cables to the Metering Unit. Refer to

the “Installation Considerations” section of the manual for more details.

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•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.

•Replace fuses with correct type, size and value. All channel fuses are Time lag

MDA (or MDL) style 3AB (or 3AG) ¼” by 1 ¼” (6.3 mm x 32mm), 250 Volt. 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 enclosure doors and module covers must be present and 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, 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, LLC 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

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:

[email protected]

DynAmp web:

www.dynamp.com

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MANUAL REVISIONS

Page

Change

Reason For Revision

Date

all

Rev NEW

6/97

Rev A

Installation Notes

12/97

Rev A

Installation Considerations

14, 15

Rev A

Measuring Head Resistance Chart

Rev A

Spare Parts List

Rev B

Drawing list

12/97

All

Rev C

Safety, Installation, & Drawing list

5/98

14,15

Rev C1

Typing Error - Table 4-1 & 4-2

9/99

All

Rev D

Warranty, Safety, Installation Considerations,

Maintenance & Spare Parts, Added Related Technical

Bulletins section

05/00

29, 36

Rev E

Updated Accuracy Diagnostics & Spare Parts section

04/02

iii, 7

Rev F

Updated Warranty and Installation paragraph

10/03

All

Rev G

Update to DynAmp, LLC, update Table 2 – Measuring

head resistance chart LKP-80

11/04

vii, 1, 34,

Rev H

Update fuse precautions per ECR 1304

07/06

ECO 3166 update accuracy diagnostics drawings/list

09/08

All J PAR 10245 – Handling & Storage, ECR 1440-

Calibration Intervals / New Manual Format 05/11

1,2,13,19

ECO 3307 – Section 1 Safety, Installation Precautions,

Metering Unit Wiring

10/16

2,23,24,36,

41 L ECR 1955 / ECO 3330 – Update fuse value for LKP-45 -

Safety, Change Note in Table 5.3 & 5.4, Spare parts list

7.1,and Drawing list size changes 9.1 11/16

6, 24, 35,

iii, xiii

ECO 3350 – Add head assembly torque, Add verbiage

to Circuit Function Description 5.4, Add drawing

revisions in Table 8.1, Remove obsolete MVI & SVI

options on 83C108255, Update title blocks in drawings,

and General verbiage updates for Customer Support &

Service and Warranty Page.

10/18

9, 35

ECO 3350 – Update verbiage under Section 4.3 and

update drawing 02A108033 revision in Table 8.1

01/20

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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 to 70°C

-40 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 DynAmp, LLC LKP Series 6 & 8 channel are systems for accurately measuring direct

current in a bus. The Models in this series are: LKP-45 and LKP-60 (6 channel), and LKP-

80 (8 channel). Each model consists of a two-piece Measuring Head, a Metering Unit, and

two multi-conductor cables. For the sake of simplicity throughout this manual, the LKP 6

and 8 channel Metering Units might be referred to as the LKP system, or LKP metering

system.

2.2 ADDITIONAL MEASURING HEAD DETAIL

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 epoxy finish,

insulation from the bus being provided by a 3/8 in. (9.5mm) layer of high-grade epoxy. The

Measuring Head halves are easily joined around the bus by use of 8 bolts.

The LKP-60 and LKP-80 Measuring Heads are provided with mounting feet as standard

equipment. The mounting feet facilitate the mounting of the Measuring Heads vertically on

the floor or on a platform. The LKP-45 can be provided with mounting feet or with a bus

bar mounting kit (both are optional).

2.3 ADDITIONAL METERING UNIT DETAIL

The Metering Unit is housed in a standard NEMA 12 enclosure (IP54). In addition to the

electronic circuitry (housed within two 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 2400 VA. A

thermo-magnetic circuit breaker is mounted on the inside of the enclosure and serves as

the power on-off control.

2.4 INTERCONNECTION CABLE DETAIL

A standard 33-foot (10 meter) interconnecting cable is supplied with each system (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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2.5 ELECTRICAL

Six outputs are provided by the system:

1. A standard voltage output exists at terminals TS2-6 and TS2-7 inside the Metering Unit.

The output voltage is 1mV/kA for model LKP-80, and 10mV/kA for models LKP-45 and

LKP-60.

2. An additional voltage at TS2-8 and TS2-9, when an optional shunt is installed.

3. A current output of 1 Adc per 5 kA of bus current, at TS2-4 and TS2-5. The current

output is available by removing a jumper connected across the terminals (do not

remove the jumper while the system is energized). Maximum allowable voltage drop

across the terminals is 15 Vdc at the normal maximum current output of the bus.

4. A normally-open (N.O.) relay contact for the Metering Unit over-temperature alarm, rated

at 120 Vac, 6 A, at TS2-12 and TS2-13.

5. A normally closed relay contact for accuracy diagnostics output at TS2-12 through TS2-

14. 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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