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1. If the head is to be installed on a T section of the bus it should be located a minimum distance of 4a from the joining point The head should be a minimum distance of 2a from another bus carrying equal or less current If the other bus carries higher current the distance should be greater e g 3a If the head is to be installed on a U section of the bus the distance between the parallel bus sections must be a minimum of 4a and the head should be centered between them Figure 5 1 General Guidelines for Locating Measuring Heads 2011 DynAmp LLC 041592 J Page 10 Installation Operation and Service Manual LKP Series 5 3 HEAD INSTALLATION There are two connector fittings on the measuring head one on each half These fittings are not to be used for lifting Proper lifting is accomplished by using eyebolts in the holes provided in the channel flanges or corners Choker slings may be used around the head as long as strong lateral pressure on the edge of the window insulation is avoided see note below Before actually installing the measuring head on the bus the head may be checked for proper operation first This is accomplished by connecting the entire system as explained in this section and then performing the head checkout procedure described in section 5 9 with the head removed from the bus After the procedure is complete the head should be mounted as explained in section 5 4 Check the mating fa2. This Page is Intentionally Blank 2011 DynAmp LLC Page 24 041592 J Installation Operation and Service Manual LKP Series 6 THEORY OF OPERATION 6 1 GENERAL CONTROL INPUT FEEDBACK BUS Z ZSZ Z Fux a Eeer COR FEEDBACI El CORE ACK CONTROL CURRENT INPUT HIGH GAIN SENSOR OUTPUT SIGNAL AMPLIFIER OUTPUT SIGNAL PROPORTIONAL TO INPUT BUS FLUX AND FEEDBACK CURRENT Figure 6 1 Magnetic Null Detector Diagram A thorough knowledge of the LKP system theory of operation is essential for efficient troubleshooting In figure 6 1 a portion of the measuring head is shown to illustrate the magnetic null principle used in all Series LKP current measuring equipment 6 2 MAGNETIC SENSOR NULL DETECTOR The magnetic sensor produces a voltage output proportional to the difference between the bus field and the feedback field The sensor output is amplified and is returned to the magnetic circuit in the form of feedback current This current is passed through 5000 turns to produce the feedback field The measuring head contains many magnetic sensors and feedback coils Each set of sensors and the adjacent coils plus the associated amplifying section of the metering unit is termed a channel Each channel responds nearly independently of the other channels to null the bus field in its own section of magnetic core However after passing through their respective coil groups all channel currents are summed to produce the out
3. 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 GENERAL DynAmp does not assume liability for the customer s failure to comply with the rules and requirements provided in this manual 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 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 Ill and pollution degree 2 INSTALLATION Symbol Identification General definitions of safety symbols used on equipment and manual A Caution Warning Refer to accompanying documents for instructions O 2011 DynAmp LLC Page v 041592 J Installation Operation and Service Manual LKP Series T
4. or replaced according to the manufacturer instructions CAUTION To avoid the risk of shock and electrocution always disconnect the AC power and head cables from the head before performing any cleaning or service operation on the metering unit Disconnect power to the system before servicing or replacing fuses 7 3 RECOMMENDED CALIBRATION VERIFICATION INTERVALS DynAmp does not specify required intervals of calibration for its products The end user of the product is responsible for identifying the appropriate interval between calibrations The intervals should be determined based on the following factors Requirements of a Quality Management System Accuracy and permissible limits of errors Purpose and usage Experience with similar products Manufacturer s recommendations Stability of the product Past history Other characteristics of the product Reference ISO IEC 17025 2005 General requirements for the competence of testing and calibration laboratories and Laboratory Accreditation Bureau Guidance for Documenting and Implementing ISO IEC 17025 2005 and Laboratory Guidance As a guideline DynAmp recommends a 24 month interval of calibration for all permanently installed products and a 12 month interval of calibration for all products used in portable applications 2011 DynAmp LLC Page 32 041592 J Installation Operation and Service Manual LKP Series 7 4 SPARE PARTS ORDERS ROUTINE OR EMERGENCY Reques
5. to the meter unit Do not short between the head structure and the bus to prevent serious damage or injury For that reason always disconnect the cables from the head prior to installation or maintenance Touching both an energized bus bar and grounded measuring head may result in electrical shock 2011 DynAmp LLC Page 12 041592 J Installation Operation and Service Manual LKP Series G H Most models interconnection cables have a GRN YEL wire that is used for head grounding To electrically float the head above ground potential the GRN YEL wire from each cable must be disconnected at the meter unit Note that for safety reasons the meter unit cabinet should be grounded at all times Do not loosen any of the bolts that hold the head casting sections together Doing so will compromise the seal between parts and allow water or contaminants to enter the head The head must be installed with current arrows in the same direction as conventional current flow in the bus An arrow indicates the direction that conventional bus current must flow through the aperture to No damage will occur if the head is reversed but an LKP system will not produce an output in this condition CAUTION The part line insulation pieces located on the mating surfaces of the head J K L contain sensitive electronic devices are brittle and can be easily damaged if one is not careful during installation Make sure that the ser
6. 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 hel dynamp com DynAmp web www dynamp com 2011 DynAmp LLC Page 35 041592 J Installation Operation and Service Manual LKP Series This Page is Intentionally Blank 2011 DynAmp LLC Page 36 041592 J Installation Operation and Service Manual LKP Series 8 RELATED TECHNICAL BULLETINS The following is a list of available technical bulletins that contain relevant information in regards to high current measurements and the use of LKP systems The technical bulletins are available upon request from DynAmp LLC Always consult the factory for a list of the latest technical bulletins TABLE 8 1 TECHNICAL BULLETIN LIST NUMBER SUBJECT TITLE DESCRIPTION 9908 External Fields Resolving External Magnetic Field Errors replaces TEC727 9907 LKP LKB LKP and LKB Sensor Mounting Guidelines and Restrictions 9905 LKP LKB Recommended Calibration Intervals for LKP or
7. LKB High Current Systems 9904 Diagnostics Self Diagnostics for DynAmp High Current Measurement systems Accuracy Diagnostics 987 LKP LKB Ferromagnetic Materials near LKP or LKB High Current Measurement Systems 749 Bus Analysis COMPUTER ANALYSIS OF MEASURING HEAD LOCATIONS IN HIGH CURRENT MEASUREMENT SYSTEMS LKP LKB Guidelines for locations of LKP or LKB High Current Systems Heads on Busses Volt hours times Ampere Hours is NOT equal to Watt hours Bus Analysis Data required for Bus Analysis of High Current Measurement Systems 2011 DynAmp LLC Page 37 041592 J Installation Operation and Service Manual LKP Series This Page is Intentionally Blank 2011 DynAmp LLC Page 38 041592 J Installation Operation and Service Manual LKP Series 9 DRAWINGS TABLE 9 1 DRAWING LIST DRAWING TITLE NUMBER Outline and Mounting LKP 45 Measuring Head Outline and Mounting LKP 60 Measuring Head Outline and Mounting LKP 80 Measuring Head Assembly Mounting Feet Option Bus Bar Mounting LKP 45 Wiring Diagram Harness Assembly LKP Series 4 Channel Assembly Control Circuit PC Board Assembly Accuracy Diagnostics Schematic LKP Accuracy Diagnostic Board Isolator Options Wiring Diagram Totalizing Diagram Outline and Mounting LKP Series 6 amp 8 Channel Metering Unit Assembly Supply amp SCR Drive PC Board Schematic LKP 4 Channel High Range Module Interconnection Diagram LKP 45 Interconnection Diag
8. and Service Manual LKP Series e The surface on which the head is mounted on must be sound and capable of supporting the head Fasteners used must be capable of supporting the weight of the head e Measuring head should be electrically isolated from the bus bars A 7 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 meter unit e 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 041592 J 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
9. are the room temperature values of the copper channel coils Measured values can be 50 higher if head is hot and or cable length is longer than 30 feet 2011 DynAmp LLC Page 14 041592 J Installation Operation and Service Manual LKP Series TABLE 5 1 A MEASURING HEAD RESISTANCE CHART LKP 45 Measure Between Leads Desired Value Circuit Ohms CABLE TO A HALF OF HEAD 2011 DynAmp LLC Page 15 041592 J Installation Operation and Service Manual LKP Series TABLE 5 1 B MEASURING HEAD RESISTANCE CHART LKP 60 Measure Between Leads Desired Value Circuit Ohms CABLE TO A HALF OF HEAD CABLE TO B HALF OF HEAD 2 53 amp 56 22 24 Coil Circuit Channel 4B 2 52 amp 58 10 5 12 Coil Circuit Channel 5 O 2011 DynAmp LLC Page 16 041592 J Installation Operation and Service Manual LKP Series TABLE 5 2 MEASURING HEAD RESISTANCE CHART LKP 80 Measure Between Leads Desired Value Circuit Ohms CABLE TO A HALF OF HEAD 5 7 METERING UNIT INSTALLATION The location of the metering unit should be determined by the following factors A An indoor location where the ambient air temperature is within 20 C to 55 C at all times should be used B The location should be within reach of the head cable length to be routed C The location should be approximately 8 feet 2 5 meters or more from high current bus bars Some installations have been made much closer to high
10. 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 envi
11. circuits are functioning properly and the system s power supplies are within specifications More specifically this indicates the following conditions exist 1 All channels have a core magnetic flux null a All components in the circuits appear to be operating normally b Input fields are of the expected polarity C Input magnetic flux appears balanced by feedback flux 2 Power supplies are operating within acceptable ranges a Mains input power is on b Hall plate sensor power supply output is correct With unidirectional LKP measurement systems it is possible that the AD circuits will give a warning indication when the system is operated at low rectifier current level even though all circuits and components are functioning properly This warning at low levels is most likely to occur if the metering system is associated with only one of several rectifiers in the area The AD outputs indicate the present condition having only a short time delay from an instantaneous condition Although the AD does not monitor absolutely every possible error condition it is an effective means of giving the user continual assurance of signal reliability A B If the Diagnostics Relay is O K and the green LED indicators are all on Continue operating normally If the Diagnostics Relay indicates a warning and one or more green indicators are off This indicates there may be measurement errors and the metering system shoul
12. gt DynAmp DIRECT CURRENT METERING SYSTEMS Model LKP 45 LKP 60 amp LKP 80 Installation Operation and Service Instructions Manual Item No 041592 Rev J DynAmp LLC 3735 Gantz Road Phone 1 614 871 6900 www dynamp com Grove City Ohio 43123 USA Fax 1 614 871 6910 helpladynamp com Installation Operation and Service Manual LKP Series This Page is Intentionally Blank 2011 DynAmp LLC Page ii 041592 J 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
13. is sent to U104 U105 and RP101 which constitutes the ramp generator The ramp generator output consists of two downward sloping ramps each 180 degrees out of phase from one another Both ramps are sent to the quad comparators U110 and U111 that are used to generate the firing pulses for the SCRs 6 8 ERROR AMPLIFIERS The error amplifier circuitry consists of U106 through U109 and associated circuitry The error amplifiers serve two purposes to amplify the Hall error signal and to filter it before sending it to the comparators 6 9 COMPARATORS AND PULSE GENERATOR The comparators consist of U110 and U111 They compare the amplified and filtered output of the error amplifiers to the two ramps generated by PLL and ramp generators Two square waves are generated at the output of these comparators one for the positive half cycle and one for the negative half pins 1 and 2 of U110 for channel 1 One square wave will be used to trigger an SCR on the positive half of the waveform and the other will be used for the other half cycle Since these square waves are too long in duration they 2011 DynAmp LLC Page 27 041592 J Installation Operation and Service Manual LKP Series cannot be used directly to drive the pulse transformer drivers The comparator output is ANDed the mathematical product of a logic AND gate with several pulses generated by the PLL The output pins 3 and 4 on U113 for channel 1 will be a pulse train whic
14. should be moved to obtain a better balance of channel voltages As a simplified example of optimizing the head position assume these readings are obtained for two pairs of directly opposite channels Chan 1 25 V and Chan 5 12 V Chan 3 36 V and Chan 7 12 V Note that it is not sufficient to consider just a few channels all channel readings must be considered for repositioning However for this simplified example the head would be raised relative to the bus to balance the channels 3 and 7 voltages and moved horizontally bringing channel 5 nearer the bus to balance the channels 1 and 5 voltages Note that 1 it would not be necessary to change the horizontal positioning since the channel 1 voltage is not excessive and 2 an absolute balance between opposing channels is unnecessary Lowering the higher readings 31 V or higher is more important than achieving perfect balance CAUTION If the head position must be changed it is important that it be kept in a vertical plane if possible The head can be mounted in a tilted plane without loss of accuracy However such mounting can impose stresses at the center joining points especially if one half is supported solely from the other half If it is necessary to tilt the head out of the vertical plane by more than 20 to achieve lower channel voltages first make sure each half is independently supported at four points and then carefully loosen the joining bolts Independentl
15. 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 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 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 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 necess
16. 0 and LKP 80 can be purchased that can simplify mounting the head to the floor or a platform The prime considerations in all cases are as follows Read and follow the following considerations before mounting the head These are detailed in Technical Bulletin No 9907 titled LKP amp LKB Sensor Mounting Guidelines and Restrictions A Choose a mounting location where the ambient air temperature does not exceed 55 C The standard head is designed for indoor use only and should be kept away from high heat and corrosive atmospheres Protect the head from direct sunlight which causes the head temperature to rise thus limiting the upper operating range in some applications If the head is to be installed in a harsh environment please discuss protective measures with the factory B The head must be protected from water The LKP and LKB sensor head designs rated 15 kA and higher are tested to meet IP 64 when manufactured indicating protection from splashing water from any direction However this rating is not a blanket approval for simply installing it outdoors without additional water protection The measuring heads are splash proof but are not waterproof Classification IP 64 acknowledges that some water may penetrate the seal Water that invades the sensor is likely to cause long term destruction Consequently it is necessary to provide some rain and snow protective covering if the equipment is to be mounted outdoors or in the vicinity
17. 1 A 5 kA 0 1 full scale Voltage output LKP 45 LKP 60 10mV per kA of bus current 0 1 full scale Voltage output LKP 80 1mV per kA of bus current 0 1 full scale 48 1219 H x 36 914 Wx 16 406 D LKP 45 Measuring Head 31 772 H x 33 839 W x 6 7 170 D LKP 60 Measuring Head 36 905 H x 40 1008 W x 11 8 300 D LKP 80 Measuring Head 45 1134 H x 48 1220 W x 11 8 300 D LKP 45 Measuring Head 20 9 530 H x 20 9 530 W LKP 60 Measuring Head 23 4 595 H x 23 4 595 W LKP 80 Measuring Head 30 5 775 H x 30 5 775 W 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 Max Core Set 6 75 amperes 9 amperes 12 amperes e See section 4 2 concerning magnetic effects of external buses 2011 DynAmp LLC Page 8 041592 J Installation Operation and Service Manual LKP Series 5 INSTALLATION 5 1 HANDLING PRECAUTIONS Even though the LKP Series systems are large and rugged they should be handled with the same care as any precision measuring instrument Larger measuring heads are quite heavy and adequate handling equipment
18. 1 General Guidelines for Locating Measuring Heads occoooccococcccccccccnnnnnonannccnnnnnnnnns 10 Figure 5 2 Window Insulation Nomenclature Typical For LKP Series Heads 11 Figure 5 3 Proper Lifting TechniQUe aci eege 13 Figure 6 1 Magnetic Null Detector Diagram 2 eccceccceee erence eeeeet eee eteeeeeeeeeeeececeeneeeeeeene 25 Figure 6 2 Functional Diagram of Four Channel System 0 cece eeenseeeeeeeeeeeeeeenenneeeeeeeeeees 26 Table 4 1 LKP Series 6 amp 8 Channel Specifications cccceecceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeneees 7 Table 4 1 LKP Series 6 amp 8 Channel Specifications Continue 8 Table 4 2 Typical Error At Zero BUS Cumrent nono nono nn 8 Table 5 1 A Measuring Head Resistance Chart LKP 45 ssssrsrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrreens 15 Table 5 1 B Measuring Head Resistance Chart Lk 16 Table 5 2 Measuring Head Resistance Chart LKP 80 0 0 0ceeeeeeeeeeeeeeeteeeeeeeeeeeeeeeeeeees 17 Table 5 3 Channel Voltage Measurements Form LKP 45 SUR 22 Table 5 4 Channel Voltage Measurements Form KP 23 Table CT Spare Parts Lists geste e A A Se es Seed 34 Table 8 1 Technical Bulletin Uiset nono nnnnnnnnnnn nn nnnnnnnnnnr ranas 37 Table 9 1 Drawing Listo es o rad 39 2011 DynAmp LLC Page xii 041592 J Installation Operation and Service Manual LKP Series 1 SAFETY 1 1 OVERVIEW This equipment is designed to be connected to hazardous electric
19. 2 6 and TS2 7 inside the meter unit The output voltage is 1mV kA for model LKP 80 and 10mV kA for models LKP 45 and LKP 60 An additional voltage at TS2 8 and TS2 9 when an optional shunt is installed 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 _Anormally open N O relay contact for the meter 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 2011 DynAmp LLC Page 6 041592 J Installation Operation and Service Manual LKP Series 4 SPECIFICATIONS TABLE 4 1 LKP SERIES 6 amp 8 CHANNEL SPECIFICATIONS MODEL MAX FULL SCALE MEASURING HEAD METERING UNIT WEIGHT RANGE WEIGHT LKP 45 45 kA 172 lb 78 kg 300 Ib 136 kg LKP 60 60 kA 297 lb 135 kg 300 Ib 136 kg LKP 80 80 kA 396 Ib 180 kg 330 Ib 150 kg Ambient Temperature Range of Measuring 20 C to 55 C Head Ambient Temperature Range of Metering unit 20 C to 55 C Location AC Line Voltage at
20. 4 15 RevA Measuring Head Resistance Chart 33 RevA Spare Parts List 35 Rev B Drawing list 12 97 All Rev C Safety Installation amp Drawing list 5 98 14 15 Rev C1 Typing Error Table 4 1 amp 4 2 9 99 All Rev D Warranty Safety Installation Considerations 04 00 Maintenance amp Spare Parts Added Related Technical Bulletins section 29 36 39 RevE Updated Accuracy Diagnostics Spare Parts section 01 02 Technical Bulletin list iii 7 Rev F Updated Warranty and Installation paragraph 09 03 all Rev G Update to DynAmp LLC update Table 2 Measuring 11 04 head resistance chart LKP 80 v 1 34 36 Rev H Update fuse precautions per ECR 1304 07 06 41 ECO 3166 update accuracy diagnostics drawings list 09 08 All J PAR 10245 Handling amp Storage ECR 1440 Calibration 01 11 Intervals New Manual Format 2011 DynAmp LLC Page ix 041592 J Installation Operation and Service Manual LKP Series This Page is Intentionally Blank 2011 DynAmp LLC Page x 041592 J Installation Operation and Service Manual LKP Series TABLE OF CONTENTS Par Title 1 SAFETY dh EE eege 2 HANDLING AND STORAGE 3 DESCRIPTION MOVERME said stand 3 2 MEASURING HEAD pao ais 4 SPECIFICATIONS 5 INSTALLATION 5 1 HANDEINGPRECAUT ON Sinai 5 2 MAGNETIC CONSIDERATIONS MEASURING HEAD ee 5 3 HEAD INSTALLATION atada 5 4 INSTALLATION CONSIDERATION SS ooooccccccconcnncccnonannncccnannnnanonanancnnnnnnnnos 5 5 INSTALLATION PRECA
21. 50 or 60 Hz 5Hz 100 120 200 220 240 Vac 10 15 Maximum Allowable Burden of Output Circuit 15 volts Linearity Errore 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 Pollution Degree y Contingent upon DynAmp LLC computer analysis of bus system SR 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 sr 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 2011 DynAmp LLC Page 7 041592 J Installation Operation and Service Manual LKP Series TABLE 4 1 LKP SERIES 6 amp 8 CHANNEL SPECIFICATIONS CONTINUED OUTPUTS Current output
22. 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 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 041592 J Installation Operation and Service Manual LKP Series This Page is Intentionally Blank 2011 DynAmp LLC Page iv 041592 J 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 are provided for locking the doors Only authorized personnel or technicians should be allowed to open and service the unit
23. UTIONS LIVE BUS 00oooooncccccccoconcconananinininananos 5 6 COMPLETING THE HEAD INSTALLAT ION eee eee e etna 5 7 METERING UNIT INSTALLATION oci imicicoin ciaci n 5 8 METERING UNIT WIRING wie cio isidro 5 9 INITIAL SYSTEM CHECKOUT rcaisdeucessaiasaps cous ge ENEE Kee 5 10 MAGNETIC CENTERING EE 5 11 REVERSING CABLE EXIT DIRECTION ON MEASURING HEAD 6 THEORY OF OPERATION Blende A AA AAA A 6 2 MAGNETIC SENSOR NULL DETECTORI cece eee erent 6 5 SYSTEM DESCRIPTION Susini 6 4 CIRCUIT BUING TIONS stc e aa aaa aa tdia apa aeea ianh taaah aeai 6 5 METERING UNIT vana dai 6 6 POWER SUPPLIES orar tia Gul SYNC E E IR EE 6 8 ERRORAMPLIFIERS gt siroritadta lo don 6 9 COMPARATORS AND PULSE GENERATOR occ eee eee 6 10 PULSE TRANSFORMER DRIVERS kk 6 11 OUTPUT CIRCUM sicscihebenmusaseretiviansencnsiginubedeostainnesipusiaraneuerveuinaeianaaeanate 6 12 ACCURACY DIAGNOSTICS OPTIONAL eee eee eeeeeeees 7 MAINTENANCE amp SPARE PARTS 2011 DynAmp LLC 041592 J Installation Operation and Service Manual LKP Series 7 1 PERIODIC MAINTENANCE oy tege ais ia 31 7 2 ANNUAL MAINTENANCE cnica air 31 7 3 RECOMMENDED CALIBRATION VERIFICATION INTERVALS 32 7 4 SPARE PARTS ORDERS ROUTINE OR EMERGENCY occiccccccccncccncccconancncccnanancninns 33 La REGOMMENDED SPARE PARTO atando ita 33 cl SERVICE ASS ISTANGE TEE 35 8 RELATED TECHNICAL BULLETINS 37 9 DRAWINGS 39 DRAWINGS 8 TABLES Figure Titles e ini EE Page Figure 5
24. ary 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 a 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 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 The measuring heads are splash proof but are not waterproof The heads are supplied with connector covers that must be used whenever the head cables are disconnected from the head The covers are necessary to prevent dust and water from entering the 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 2011 DynAmp LLC Page 1 041592 J Installation Operation
25. aximum bus current 5 Anormally open N O contact for the meter unit over temperature alarm rated at 120 Vac 6 A at TS2 10 and TS2 11 6 Optional isolated shunt output Scaling is per customer order 0 10V 4 20mA available Burden resistors inserted in the series output circuit should be selected with care The wattage rating should be at least two times higher than the calculated power dissipation The burden resistor should have a low temperature coefficient 25 ppm or better The LKP 6 and 8 channel meter unit is supplied with a two pole circuit breaker mounted inside the enclosure on the main panel 6 12 ACCURACY DIAGNOSTICS OPTIONAL ACCURACY DIAGNOSTICS AD is a system that assures the user that most internal circuits are operating properly and it is also a diagnostic tool It is made up of a number of circuits monitoring conditions of many of the critical components circuits and connections within the current monitoring system The AD subsystem provides relay contacts for the user to connect to his remote warning indicator The AD diagnostic light emitting diodes on each meter unit module indicate proper operation of associated circuits On some larger 2011 DynAmp LLC Page 28 041592 J Installation Operation and Service Manual LKP Series systems a red warning light mounted on the enclosure door provides a simple visual warning refer to wiring diagram for this feature The AD indicates the feedback
26. between the cable connector and the mating head connector F Inspect the condition of the pins and sockets and clean out any corrosion G Visually inspect metering unit and signal converter s for evidence of severe overheating or excessive corrosion Record any suspect conditions and take appropriate action 2011 DynAmp LLC Page 31 041592 J Installation Operation and Service Manual LKP Series H Inspect all bolts on the head and torque any that might have come loose Observe proper torquing techniques and specs carefully l Clean the following items 1 Cables and external surfaces of measuring head and metering unit Clean as necessary remove any oil or grease with a mild detergent or cleaner solvent Do not use strong chemical solvents as they may damage the cables or erase the silk screening from the metering unit 2 Metering unit interior should only be performed after disconnecting power to the metering unit Dust and dirt can be removed by gently vacuum cleaning the unit Be careful not damage the internal shunt Solvents should never be used on any of the PC boards The boards are coated with a protective conformal coating which can be stripped away by certain solvents J Check the electrolytic filter capacitors for seals that have been popped degassed or are leaking electrolytic fluid Replace if necessary K If the unit is equipped with a cooling fan and filter then the filter should be cleaned
27. ces of the measuring head Make absolutely certain that the serial numbers of both halves of the head match otherwise you may cause misalignment and unit failure Remove any dirt particles from the head part line insulation and multi conductor connector When installing the measuring head protect the window insulation from impact and do not let the weight of the measuring head rest upon the window insulation as it can be easily damaged Also the interconnecting cable is of top quality but it is not armored Protect it from abrasion and sharp edges A HALF PART LINE 20 A ULATION INSULATION VERTICAL NSULATION ORNER 8 HALF Figure 5 2 Window Insulation Nomenclature Typical For LKP Series Heads The head must be installed with current arrows in the same direction as conventional current flow in the bus No damage will occur if the head is reversed but the system will not produce an output O 2011 DynAmp LLC Page 11 041592 J Installation Operation and Service Manual LKP Series 5 4 INSTALLATION CONSIDERATIONS In general the head can be installed vertically horizontally or in any intermediate orientation The LKP 45 can be mounted by using the Busbar mounting kit purchased separately Alternatively optional mounting feet standard on LKP 6
28. current buses without difficulty but the distance given is on the safe side D Mount the metering unit on a wall column instrument panel or other convenient location refer to outline and mounting diagram in the back of the manual O 2011 DynAmp LLC Page 17 041592 J Installation Operation and Service Manual LKP Series 5 8 METERING UNIT WIRING Terminate all conductors from the head as shown in the interconnection diagrams in the back of this manual As an aid to wiring each conductor is identified by a numbered sleeve or imprinted numeral which corresponds to the correct terminal destination You should always use the wire numbers when making connections as wire colors may vary or appear different under certain lighting conditions If the wire ends get damaged and require re stripping use high quality wire strippers and set the strip length to 0 39 10mm Install and connect the output monitoring devices to the appropriate terminals at the metering unit If current output is used remove the factory installed jumper and connect the desired current output circuitry using an adequate wire size Make sure that the burden imposed by the wire is not excessive If bus current is on bus ripple or sudden changes in bus current level will induce significant voltages in the feedback coils Therefore the cables must be disconnected from the head while wiring them to the meter unit Complete the wiring job by connecting t
29. d has been properly centered electrically the information may prove valuable in the event of any future malfunction It is a good idea to take an additional set of readings at the hottest time of the year especially if the equipment is exposed to outdoor temperatures space is provided for the recording of three sets of readings NOTE Although the channel voltages may vary widely with temperature extremes the accuracy will remain unaffected so long as each channel voltage falls within the limits of 3 V to 40 Vdc Channel voltages are measured between terminals at the metering unit terminal block with the LKP in service on an energized bus INSTRUCTIONS Record the channel measurements for every channel make additional copies of this form as needed 2 Supply the information called for below CHANNEL VOLTAGES Volts Volts TS1 25 to 30 TS1 26 to 30 Volts LKP 45 amp LKP 60 Volts TS1 24 to 30 HEAD 781 27 to 30 Volts Volts TS1 49 to 56 TS1 52 to 56 Ambient Temperature Date LOOP BURDEN TS2 4 8 5 LINE VOLTAGE TS1 2 amp 3 BUS CURRENT kA Serial Number of LKP 45 or LKP 60 NOTE The channel voltages should be between 3 and 40 Vdc read notes in Magnetic Centering section of the manual carefully 2011 DynAmp LLC Page 22 041592 J Installation Operation and Service Manual LKP Series TABLE 5 4 CHANNEL VOLTAGE MEASUREMENTS FORM LKP 80 If the chan
30. d not be in full automatic control of the rectifier The AD relay contact output is not intended to be the only monitor protecting the power rectifiers Primarily it is expected that the customer wants to take immediate action to prevent unsafe operation Unsafe operation could result if the metering system is in the rectifier control loop and it erroneously produces a significantly lower output than is true This might cause the rectifier control circuit to inappropriately increase the power output perhaps to overload levels for either the power supply or the process So if the metering system is in the control loop and the Accuracy Diagnostics indicates a potential problem the following actions are recommended FIRST Lock out control actions that could drive the rectifier output higher and SECOND alert the operator Basically each module inside the metering unit has 4 channel LEDs and two line monitoring LEDs The following is a description of their functionality A Line This LED indicates whether the supply voltage to the meter unit falls within the specified limit of 10 15 of nominal Significant changes from these values will cause this LED to turn off and trip the relay Hall P S This LED indicates whether the Hall plate supply voltage supply voltages fall with the specified operating limits A failed Hall plate power supply or a line voltage out of specification will extinguish this LED and trip the relay 2011 Dy
31. e 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 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 3 3 METERING UNIT 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 3 4 CABLE 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 meter unit Keyed connectors are provided on the measuring head side of the cables to ensure correct hookup 2011 DynAmp LLC Page 5 041592 J Installation Operation and Service Manual LKP Series 3 5 ELECTRICAL Six outputs are provided by the system 1 A standard voltage output exists at terminals TS
32. ead terminals will result if metal parts of the head contact the bus 5 6 COMPLETING THE HEAD INSTALLATION With the head temporarily installed and bus current off or the head removed from the bus for verification prior to installation complete the following steps A B Connect the interconnecting cable directly to the measuring head Note that the connectors are keyed and can only be connected one way Before connecting the other end of the interconnecting cable to the metering unit perform the ohmmeter tests in table 5 1 The tests are made from the open end of the cable looking back towards the measuring head Record these values for future reference You cannot get good ohmmeter readings if the head is on a live bus The coils pick up induced voltages from any rectifier ripple The Hall plate resistance changes in a high magnetic field Notes on Table 5 1 amp 5 2 below 1 23 3 BUS CURRENT MUST BE ZERO OR HEAD REMOVED FROM BUS when taking resistance measurements Use a high impedance DMM set on the lowest range appropriate for the measurement Measurements are made between cable leads listed at metering Unit end of Cable The resistance values shown in the table are for readings obtained with cable disconnected from the meter unit Split channels 1 and 4 5 in LKP 80 will read half the resistance values when measured with all the cables connected to the meter unit These resistance readings
33. f 5000 1 the bus current can be measured accurately by summing the independent feedback currents h l4 l2 l3 l4 Therefore the bus current is equal to 50001 Moving the measuring head with respect to the bus will cause the values of the individual feedback currents to change but will not affect the total current nor the accuracy of the measurement 6 4 CIRCUIT FUNCTIONS For the following discussion refer to the High Range Module Schematic and system schematic drawings as appropriate These drawings are located in the back of the manual Before discussing the various circuit functions a general description of the metering unit will be helpful A metering unit may consist of one or more modular units Each modular unit contains the necessary circuitry for four channels of amplification The metering unit also contains one main power transformer circuit breaker and the resistors or shunts to develop output voltages A 4 channel system is used here as an illustration to simplify the explanation Beginning at a magnetic sensor in the measuring head we can trace the signal path To achieve a signal output in the presence of a magnetic field the sensor Hall plate must be supplied a small exciting current This current is called the control current l lt and it is approximately 6 mA dc for each sensor The control current is derived from the 12 Vdc 2011 DynAmp LLC Page 26 041592 J Installation Operation and Service Ma
34. h will be used to drive the pulse transformer drivers Pulse train triggering is an advantage when noise on the line turns off an SCR The SCR is re triggered allowing a minimum off time Since these pulses are fixed and do not move if they alone were used to drive the SCRs the output would be very jumpy This was smoothed by also anding the comparator with an integrated output of itself to give the output pulse train infinite resolution 6 10 PULSE TRANSFORMER DRIVERS The pulse transformer drivers consist of U203 U204 and associated circuitry A pulse train signal is sent into the drivers pin 2 and 1 of U203 for channel 1 These drivers are open collector outputs which drive the pulse transformers T203A and T203B for channel 1 The secondary of the pulse transformer develops a current pulse which drives the associated SCRs SCR pack 1 for channel 1 6 11 OUTPUT CIRCUIT Six outputs are provided by the system 1 A standard voltage output of 10 mV kA at TS2 6 and TS2 7 for LKP 45 and LKP 60 2 A standard voltage output of 1 mV kA at TS2 6 and TS2 7 for LKP 80 3 An optional voltage output of 1 0 Vdc at full scale rating at TS2 8 and TS2 9 4 A current output of 1 A dc per 5 kA of bus current at TS2 4 and TS2 5 The current output is available by removing a jumper connected across the TS2 terminals do not remove the jumper while the system is energized Maximum allowable voltage drop across the terminals is 15 Vdc at m
35. he external power lines to terminals TS1 3 COMMON TS1 2 HOT and TS1 1 GROUND in the metering unit An external fused disconnect or circuit breaker is recommended for additional control of input power Use a 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 a temperature rating of 80 105 C If an external transformer is being used to supply power to the meter unit consider sizing the transformer to 30VA kA Over sizing the transformer will keep its temperature rise to a minimum due to the harmonic rich content of the AC current drawn by the meter unit 5 9 INITIAL SYSTEM CHECKOUT Recheck all wiring connections against the drawings to ensure proper installation When they are satisfactory turn on the system by first closing the external breaker or disconnect if used and then the meter unit circuit breaker Confirm that the amber POWER lamp is ON With the bus energized the meter unit s output in use should accurately measure the bus current However it is now necessary to take a complete set of channel voltage readings These readings serve two purposes One to verify that all channels are operating properly and two to aid in magnetic centering of the head With the bus current operating at its highest operating level take two sets of readings the first set taken immediately to verify no condition exists that may cause damage to
36. his Page is Intentionally Blank 2011 DynAmp LLC Page vi 041592 J 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 hel dynamp com DynAmp web 2011 DynAmp LLC 041592 J www dynamp com Page vii Installation Operation and Service Manual LKP Series This Page is Intentionally Blank 2011 DynAmp LLC Page viii 041592 J Installation Operation and Service Manual LKP Series REVISION PAGE Page Change Reason For Revision Date All Rev New 6 97 10 RevA Installation Notes 12 97 12 RevA Installation Considerations 1
37. ial number on the top half of the measuring head matches the serial number of the lower half and that the halves go together squarely and evenly without forcing twisting or cocking Try to mount the head in an area free of other bus bars This is not an essential requirement if a satisfactory magnetic centering can be achieved Final head position will be determined by the magnetic centering process so the head support members should be temporary at first If a bus analysis has not been performed the head should be geometrically centered on the bus during the initial installation If a bus analysis was performed follow the recommendations for initial positioning and also perform the centering process M After final magnetic centering the head must have adequate support Figure 5 3 Proper Lifting Technique 2011 DynAmp LLC Page 13 041592 J Installation Operation and Service Manual LKP Series 5 5 INSTALLATION PRECAUTIONS LIVE BUS If the unit is to be installed on a live bus the following precautionary measures must be taken before installing the measuring head A B Make sure that the cables are disconnected form the head during installation Always follow all local and plant safety procedures WARNING 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 l
38. must be available Severe jolts or bumps to the head or metering unit may cause movement of internal parts and possibly a malfunction It is also advisable to avoid supporting the head halves by the windows insulation The window insulation is tough but brittle Personnel involved in the installation should be experienced with equipment of similar size and weight They should also be familiar with the technical terms warnings and instructions in this manual and all plant safety rules and be able to follow these The complete system should be inspected for shipping damage at the earliest opportunity Visible damage must be reported to the carrier immediately Concealed damage not evident until the system is operated must be reported to DynAmp LLC immediately 5 2 MAGNETIC CONSIDERATIONS MEASURING HEAD The LKP metering systems are designed and built for accuracy stability and reliability However these factors may be adversely affected by the arbitrary location of the measuring head without regard for magnetic fields Secondary magnetic fields emanating from angled sections of the bus being monitored or from other nearby buses may cause overheating Currents from other buses produce magnetic fields which can sometimes cause zero offsets and errors at low current levels To guard against these problems a computer analysis of the bus system should be performed If a bus analysis is not feasible the guidelines presented this section can be u
39. n general the metering unit s 0 1 accuracy is only guaranteed when the primary bus current is above 5 of the full scale rating of the unit A relay contact output is available to connect to a remote warning system The relay is closed under normal operating conditions and opens when a fault condition occurs The output connections are available via a connector located on the left side of the metering unit The terminals are designated on the appropriate interconnection diagram The terminals are used as follows Contact Terminals Condition TS2 12 13 TS2 13 14 Fault condition zero bus current or meter unit turned off See notes above on zero bus current condition 2011 DynAmp LLC Page 30 041592 J Installation Operation and Service Manual LKP Series 7 MAINTENANCE amp SPARE PARTS 7 1 PERIODIC MAINTENANCE As is true with any electronic circuitry proper maintenance will prolong the service life DynAmp LLC recommends the following program be performed at the recommended interval to prevent or detect damage to the LKP system and to ensure continuing high accuracy performance Always use appropriate measures to correct any problems found Following the suggested maintenance schedule may assist in early diagnosis of problem s to minimize repairs and down time IMPORTANT NOTE Keep organized accurate recorded data forms etc from each Periodic Maintenance This information may be invaluable in trouble
40. nAmp LLC Page 29 041592 J Installation Operation and Service Manual LKP Series C Channel LEDs Each channel LED indicates the status of the corresponding channel to aid quick troubleshooting An extinguished channel LED can be caused by the following a A blown channel fuse b abad connection between the cable and the metering unit or cable and measuring head a bad Hall device in the head an open or shorted coil in the head a primary current that exceeds the dynamic measuring range of the metering unit the primary current is too low to activate all channels properly o open a strong external magnetic field causing a channel reversal Notes on items f and g above 1 2 Under certain conditions external magnetic fields can reverse one or more channels in the head The accuracy indicators will show an error in those channels until the bus current level rises high enough to effectively turn on all channels 2 3Vdc is the minimum reliable channel voltage This condition can cause false alarms For more information on this please refer to technical bulletin TEC9908 Resolving External Magnetic Field Errors In some installations when the channel voltages are balanced the channel LEDs will remain on even though the bus is turned down to zero In this case the accuracy diagnostics circuit is in an unstable condition and alarm faults as indicated by the channel LEDs should be ignored Note that i
41. nd channels with low readings will be nearer the bus Whether or not the head should actually be moved depends on three factors A The possible impracticality or difficulty of moving the head because of support system requirements clearances available etc B The necessity of moving the head because of voltage readings that are too high or too low for certain channels C The desirability of moving the head to obtain a better balance of channel voltages Study the initial voltage readings First if none of the readings are below 3 V or above 30 V the head position may be left as is If some of the voltages are in the 31 40 V range a change should be considered In some cases a channel fuse might blow if the channel voltage is above 35 volts In those cases the head will have to be moved or if the head can t be moved then a higher rated fuse can be installed Using higher rated channel O 2011 DynAmp LLC Page 19 041592 J Installation Operation and Service Manual LKP Series fuses shall be evaluated and approved by the factory only on a case by case basis If any readings are over 40 V the head must be moved As the voltage readings are compared from channel to channel around the head a pattern may be observed which indicates that a section of adjacent channels has higher than average readings whereas the section 180 across the bus has lower readings Looking for patterns of this type will help in deciding how the head
42. nel voltages are measured and recorded at least two hours after the LKP system is energized has been properly centered electrically the information may prove valuable in the event of any future malfunction It is a good idea to take an additional set of readings at the hottest time of the year especially if the equipment is exposed to outdoor temperatures space is provided for the recording of three sets of readings NOTE Although the channel voltages may vary widely with temperature extremes the accuracy will remain unaffected so long as each channel voltage falls within the limits of 3 V to 40 Vdc Channel voltages are measured between terminals at the metering unit terminal block with the LKP in service on an energized bus INSTRUCTIONS 1 Record the channel measurements for every channel make additional copies of this form as needed 2 Supply the information called for below CHANNEL VOLTAGES Volts Volts Ve E TS1 26 to 30 TS1 25 to 30 TS1 27 to 30 Volts i TS1 24 to 30 TS1 28 to 3 Volts GEES Volt TS1 51 to 55 Nelle TS1 49 to 55 Ambient Temperature Date LOOP BURDEN 182 4 amp 5 LINE VOLTAGE TS1 2 amp 3 BUS CURRENT kA AAA 2 2 Serial Number of LKP 80 NOTE The channel voltages should be between 3 and 40 Vdc read notes in Magnetic Centering section of the manual carefully O 2011 DynAmp LLC Page 23 041592 J Installation Operation and Service Manual LKP Series
43. nual LKP Series power supply in the metering unit Since the sensor resistance is low about 200 ohm the sensor current is limited by two 1500 ohm resistors one on each side of the sensor These resistors are located in the measuring head With a constant dc control current applied to a sensor in the presence of a dc magnetic field the sensor output is a dc voltage proportional to the dc field The sensor output voltage is conducted via the interconnecting cable to the metering unit where it becomes the signal input 6 5 METERING UNIT Although each modular unit contains only two circuit boards it is comprised of several sub circuits Each of these circuits is described in the remaining paragraphs 6 6 POWER SUPPLIES The LKP module contains a 15 Vdc power supply which powers only the on board circuitry The first module in the meter unit also referred to as Module A contains a 12 Vdc power supply for the Hall devices 6 7 SYNC PLL AND RAMPS The metering unit employs phase locked loop circuitry for synchronization of the firing pulses of the SCRs This particularly is an advantage when there is a high noise level present on the line voltage The PLL circuitry consists of U101 U102 and associated circuitry The line voltage is sensed at TP 4 It is then filtered and sent to U112 to be converted into a square wave and then to the PLL circuitry The output of the PLL is a square wave and is present at TP 2 This signal
44. ny of the channel readings do indicate trouble refer to Theory of Operations and Maintenance amp Spare Parts sections and resolve the problem then proceed with Magnetic Centering Note 1 Low Readings A very low amplifier output voltage may be normal for certain channels however ripple can be as high as 3 V on a non operating full off channel Thus a very low reading i e 2 V to 5 V should be suspected as a possible problem subsequent head movement or other magnetic change may show that the channel is good A blown channel fuse can cause a low reading Note 2 High Readings The maximum allowable channel output of 40 V relates to the maximum heat dissipation that the channel can safely handle A reading of 30 V to 40 V makes a change in head position highly desirable A reading exceeding 40 V makes a head position change necessary A reading of 70 75 V indicates a full on channel condition or a blown channel fuse and requires immediate action to resolve the problem A reading of 35 38 V when immediately adjacent channels are significantly different may indicate that one of the two SCRs in the channel has failed 5 10 MAGNETIC CENTERING The distribution of load or heat among all channels will be optimized by magnetic centering of the head relative to both the bus and the total magnetic environment of the head In general this simply means moving the head so that channels with high voltage readings will be farther from the bus a
45. of a sprinkler system C To minimize distortion of the magnetic field as seen by the head temporary and final support members should be nonmagnetic for example aluminum beams struts or stranded cables or wood fiberglass or Phenolic where appropriate It is recommended to keep large structural magnetic materials at least 2 meters distant from the measuring head For additional details refer to Technical bulletin No 987 titled Ferromagnetic Materials Near LKP or LKB Current Sensors D The head is designed to be supported from the bottom The top half should be attached to an anti tipping brace Never suspend the head by the top half alone If the heads are to be mounted in a position other than vertical each half of the head should be independently supported Additional drilling of the head is NOT authorized as damage may result E When mounted the two head halves of the head should be in the same plane so no distortion of the part line will occur No tension twist or excessive pressure should be applied to the part line F The head should be electrically insulated from the bus A 6mm 1 4 minimum distance between the bus and window insulation should be maintained in dry clean air More separation should be maintained if the bus voltage is greater than 1000 Volts or if the air quality is bad This will insure electrical isolation of the head structure from the bus The aluminum head structure is grounded via the cables
46. pare Parts LKP 45 Kit Spare Parts LKP 60 Kit Spare Parts LKP 80 Spare Parts Kit includes Module Fuses and Bulb as one package LKP Hi Range Module A Bulb POWER ON light Fuses LKP 45 channel fuse 3 Amp 5 per box Fuses LKP 60 channel fuse 4 Amp 5 per box Fuses LKP 80 channel fuse 4 Amp 5 per box Fuse Module ac Supply located on TS1 9 6 25 AMP All Options Accuracy diagnostics PCB 4 Channel main board 1 used in LKP 45 60 or 80 Accuracy diagnostics PCB 2 Channel main board 1 used in LKP 45 or 60 Accuracy diagnostics PCB 4 Channel main board 1 used in LKP 80 KR For one to five units stock the quantities shown For six or more units a complete system head cable and metering unit should be kept on hand ne All Fuses are Time lag MDA style 3AB Y by 1 6 3 mm x 32mm 250 Volt se Only required if accuracy diagnostics option is installed Disconnect power to the system before servicing or replacing fuses 2011 DynAmp LLC Page 34 041592 J Installation Operation and Service Manual LKP Series 7 7 SERVICE ASSISTANCE 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
47. put current This current which is always in the ratio of 1 A to 5000 A of bus current is passed through resistors or shunts to develop voltages for the meter and proportional outputs The output current itself is also available at the output terminals which are jumpered if not used 6 3 SYSTEM DESCRIPTIONS Effects of stray fields are nullified by joining a number of magnetic assemblies like the one just described in a closed path around the bus Figure 6 2 shows four such assemblies 2011 DynAmp LLC Page 25 041592 J Installation Operation and Service Manual LKP Series referred to as a 4 channel assembly A 4 channel system is used here as an illustration to simplify the drawing and explanation Magnetic a 1 Detector Magnetic Core Piece 11 12 13 14 IT 1 Burden See Resistor Amplifier a ES Return o En O Figure 6 2 Functional Diagram of Four Channel System A magnetic null detector sensor high gain current amplifier and feedback coil are combined to form one channel or current feedback loop The function of each current loop current l4 l2 Is or l4 is to maintain a state of zero flux in its related segment of the iron core A burden shunt placed in series with the total current l develops an output voltage Eo proportional to l The common side of the shunt is returned to the four high gain current amplifiers Since the bus current is directly proportional to the total current by a ratio o
48. pwards This is to facilitate routing the cables through conduit However there are instances when it is desirable to have the top cable on head half A cable A point downward to allow for the installation of a shroud or weather protecting enclosure directly above the head The following procedure is for changing the top cable exit direction 1 2 3 Disconnect ac power to the meter unit Disconnect the top cable from the measuring head Note the original position of the guide pins and guide sockets located at he corners of the connector Remove the guide pins and sockets Gently pull out the connector pin housing being careful not pull excessively on the delicate cable wires Rotate the pin housing Y a turn 180 and reinsert into the connector Reinstall the guide pins and sockets in a pattern directly opposite the original position i e replace the sockets with the pins and the pins with the sockets Reconnect the cables to the head and reapply ac power to the meter unit Warning With the system on a live bus the ac power is off and the cable disconnected from the head a shock hazard exists on the measuring head connector terminals 2011 DynAmp LLC Page 21 041592 J Installation Operation and Service Manual LKP Series TABLE 5 3 CHANNEL VOLTAGE MEASUREMENTS FORM LKP 45 amp LKP 60 If the channel voltages are measured and recorded at least two hours after the LKP system is energize
49. ram LKP 60 Interconnection Diagram LKP 80 Schematic LKP 45 amp 60 Metering Unit Schematic LKP 80 Meter Unit Wiring Diagram LKP 45 Measuring Head Wiring Diagram LKP 60 Measuring Head Wiring Diagram LKP 80 Measuring Head Wiring Diagram LKP 45 amp 60 Metering Unit Wiring Diagram LKP 80 Metering Unit 2011 DynAmp LLC 041592 J 020108100 020108101 020108102 020108256 86 33 15 68 830108030 75A108104 07A109083 05B 109034 830108255 020108033 02D107876 75B108106 05B108074 02D107939 02D108197 02D107941 05D107949 05D107951 83B 107967 83B 107968 83B 107969 83D107944 83D107946 Page 39
50. ronmental 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 041592 J Installation Operation and Service Manual LKP Series This Page is Intentionally Blank 2011 DynAmp LLC Page 4 041592 J Installation Operation and Service Manual LKP Series 3 DESCRIPTION 3 1 OVERVIEW The DynAmp LKP Series 6 amp 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 meter units might be referred to as the LKP system or LKP metering system 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 epoxy finish insulation from the bus being provided by a 3 8 in 9 5mm layer of high grade epoxy Th
51. sed as a starting point FREE BUS ANALYSIS The general guidelines below should be applied only when a detailed analysis of your bus system is not available DynAmp LLC will perform one detailed computer analysis of the proposed location of the measuring heads within your bus system at no charge Generally this is done before or at the time the unit is ordered In this way you are assured that your LKP system will function properly Whenever possible the head should be installed on the longest straight run of the bus that is available in an area free of other bus structures General guidelines requiring consideration when installing a measuring head are shown in figure 5 1 guidelines illustrated are to be considered as the minimum required distances If the proposed head location can be physically described by more than one of the diagrams figure 5 1 a bus analysis should be performed For the guidelines of figure 5 1 to apply the bus height to width ratio should equal the head aperture height to width ratio within 10 This ratio does not affect the accuracy of the measurement but it does affect the loading of different sections of the measuring head 2011 DynAmp LLC Page 9 041592 J Installation Operation and Service Manual LKP Series a maximum aperture dimension E xw Es Za min OTHER BUS The head should be located a minimum distance of 2a from a 90 bend in the bus 1 Center 4a min l
52. shooting a malfunctioning LKP system 7 2 ANNUAL MAINTENANCE Perform the following steps at least once per year If LKP system equipment is exposed to outdoor temperatures DynAmp LLC recommends these steps be performed during the hottest time of the year The following procedures should be performed at the recommended interval to prevent or detect damage to the LKP system and to ensure continuing high accuracy performance Use appropriate measures to correct any problems found A Repeat voltage measurements given in Magnetic Centering procedure to ensure that no significant change has occurred from the data recorded at startup A large change in the amplifier output voltage of a given channel compared to other channels may indicate trouble in the channel If all channels change proportionally then that might indicate a change in the bus current A lesser but significant change in a voltage measurement should be corrected by re centering the head Remember that channel voltages will vary slightly depending on the ambient temperature of the head B Measure and record the Hall device dc power supply voltage C Visually inspect measuring head and interconnection cable for evidence of severe overheating or excessive corrosion Record any suspect conditions D Inspect and touch up the seals between the window insulation and the aluminum frame of the head Reseal as necessary E Inspect amp replace if required the gasket
53. the LKP meter unit and the second set after a 24 hour period of time to thermally stabilize the head Proceed as follows A The dc voltage range may be as high as 75 Vdc point D below Make certain the voltmeter being used is set to measure average dc volts in this range B The measured bus and all other high current buses in the vicinity or in the facility within 10 20 meters away should be operating at or near their highest levels Note All magnetic field sources will affect the channel voltage readings 2011 DynAmp LLC Page 18 041592 J Installation Operation and Service Manual LKP Series C Make a photocopy of table Form for Recording Channel Voltage Measurements The initial readings are made as instructed on the form and are recorded in the individual blocks which graphically show channel locations on the head D Excluding the effects of external magnetic sources and assuming a full rated bus current each channel is expected by calculation to measure approximately 18 V to 30 Vdc In practice channel readings should be more on the order of 10 V to 30 Vdc but that may not be achievable A channel failure will usually be indicated by either a full off near zero half on 35 38 V or full on 70 75 V condition CAUTION Avoid operating the unit for an extended time with any channel output over 40 V This will permanently damage the system For voltages over 40 V consult the factory E If a
54. ts for spare parts should be directed to Service at DynAmp LLC during normal hours When contacting us please present as much information as possible such as the related equipment Model and Serial Numbers available on the equipment tag the required part name its DynAmp LLC item number and other identifying or vendor number s and your time needs An approved Purchase Order Number should be given with your order 7 5 RECOMMENDED SPARE PARTS The following table lists the minimum recommended quantities for spare parts for the LKP Series 6 amp 8 Channel As spares are used replacements should be ordered Since continuous operation of high current measurement systems is usually critical stocking spare parts should be given high priority A single module A kept on hand see part number below can be used to replace either of the modules in the meter unit and guarantee quick error free repair Note that a module B cannot be used to replace a module A but the reverse is true The LKP Series measuring heads require special repair procedures and materials However the heads are very reliable and should require little or no repair over its service life Please refer to the nearest authorized DynAmp service center for information on repairs 2011 DynAmp LLC Page 33 041592 J Installation Operation and Service Manual LKP Series TABLE 7 1 SPARE PARTS LIST DESCRIPTION ITEM NO QUAN Metering Unit Kit S
55. y move each half into the new position visually align Firm up the support system and re bolt A gap of at least in 7 mm must be maintained between any part of the head and bus to prevent possible buildup of a conductive dust path between them Using the initially recorded channel data move the head position as necessary or desirable observing the above precautions Make spot readings of the channels in question to confirm results When the spot readings are satisfactory record their values and measure and record the values of all other channels on the diagram in table Form for Recording Channel Voltage Measurements Additional copies may be made to use for spot readings or trial runs Check the diagram to see if the position is now satisfactory Once balance is apparently achieved it is advisable to let the system operate 24 hours to thermally stabilize the head Then make any necessary adjustments and record the final position values on one of the book copies of the table and label accordingly This data will be valuable for future troubleshooting or maintenance When the desired final position of the head has been obtained return to section 5 6 step b to complete the system installation 2011 DynAmp LLC Page 20 041592 J Installation Operation and Service Manual LKP Series 5 11 REVERSING CABLE EXIT DIRECTION ON MEASURING HEAD The cables are normally connected to the measuring head such that both cables point u
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