MODEL COP-D/DC and COP-D/RMS
Contents
1. 10 Figure 7 1 Typical TeSt COM der tne 14 Fig r 7 2 TeSt Gol 15 Figure 7 3 Test Coll Circuit Diagram 15 Figure 8 1 Battery Pack Connector Wiring 19 Figure 8 2 Charger Cable Connector Wiring 20 Table Ai es tear Mascon ei 5 Table 4 1 SS 6 Fable 9 1 Spare Parts Listes css ates 24 Table 10 1 Drawing oer ncaa dete 25 2012 DynAmp LLC Page xii 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 1 SAFETY 1 1 OVERVIEW The Model COP System is intended for use where the operator is either totally electrically isolated or essentially at the same potential as the bus Ignoring the operating precautions and warnings can result in severe personal injury or equipment damage The following are general guidelines that should be followed when using the meter unit and head The operator must be a quali2. Note 2 The Model COP System is intended for use where the operator is either totally electrically isolated or essentially at the same potential as the bus Note 3 Maximum measurement range is limited only by the size of the bus that the head can encompass and the maximum range of the meter unit the head is used with The meter unit must be calibrated for the model and size of measuring head it is to be used with 2012 DynAmp LLC Page 6 041663 J Installati on Operation and Service Manual COP D DC and COP D RMS 5 ENVIRONMENTAL AND SPECIAL CONSIDERATIONS 5 1 GENERAL The COP D is a precision instrument as such it should be handled with the care normally associated with high accuracy electronic equipment 5 2 MECHANICAL 5 3 E 5 4 5 Materials comprising the measuring head have been selected to protect components internal to the structure Consequently care should be exercised when closing the measuring head and when placing it around a conductor Although the head housing is a tough fiberglass filled plastic it will not withstand repeated jarring or rubbing against sharp abrasive surfaces LECTRICAL The meter unit offers excellent long term electronic and temperature stability due to the use of high quality components Electrically there should be no significant changes in operating parameters over an extended period of time In event that calibration does appear necessary refer to Calibration section in thi
3. and least fatigue Figure 6 1 Proper wear of the COP D b Connect the measuring head cable to the mating connector on the meter side c Turn the FUNCTION SELECTOR switch to BATTERY TEST Test is satisfactory if neither LOW light comes on If either light illuminates reverse the position of the ALTERNATE BATTERIES switch If either light is on recharge the battery pack if both lights are off proceed with step d Note If the batteries have been fully discharged neither of the LOW lights can come on and the battery test will have appeared to be satisfactory When the DRIFT position is selected the digital readout will be blank If these conditions exist recharge the battery pack for 6 8 hours or longer if needed d Adjust for minimum drift of the digital readout as follows the adjustment is made to stabilize the readout at any given value rather than to obtain a zero readout 1 Close the measuring head NOT around a bus or conductor DO NOT move the head during the drift adjustment For best results lay the head down on a flat surface before making this adjustment 2 Turn the FUNCTION SELECTOR switch to DRIFT 3 Hold the RESET toggle left or right until the readout is zeroed 4 Loosen the DRIFT ADJUST lock ring turn CCW 2012 DynAmp LLC Page 10 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 5 Observe digital readout polarity and value If readout is becoming more positiv
4. either totally electrically isolated or essentially at the same potential as the bus Ignoring the warnings can result in severe personal injury or equipment damage To avoid the risk of electrical shock the safety instructions and guidelines in this manual must be followed The electrical specifications must not be HAZARDOUS exceeded and the unit must be used according to directions provided VOLTAGE Symbol Identification General definitions of safety symbols used on equipment and in manual Caution Warning Refer to accompanying documents for instructions 2012 DynAmp LLC Page v 041663 J Installation Operation and Service Manual COP D DC and COP D RMS This Page is Intentionally Blank 2012 DynAmp LLC Page vi 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 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 Se
5. 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 installatio
6. together Connect 4 9 to 5 1 Vdc power to pin 3 common and pin 5 V of the meter Allow the meter to warm up for at least 1 minute Connect an input signal 0 to 200mVdc to pins 3 common and 11 signal input Adjust this signal level to exactly 190mVdc If the meter does not read 190 use the gain adjustment located on the back of the meter to make the meter read 190 Control pins for decimal points in the display are brought out the back of the meter for external programming The required decimal point is lit by connecting the appropriate meter pin 4 5 or 6 to the supply common pin 3 You can test these using the pin connection designations below PIN CONNECTORS Analog Gnd 6 D P 100 Digital Gnd 7 Input HI D P 1 55 8 Input LOW D P 10 9 Hold 3 Battery 10 Dec Pt Supply Meter will hold when pin 9 is grounded Decimal point is active when connected to pin 10 Display test You may test the display by connecting pin 2 to pin 1 This will activate all meter LED segments except the decimal points The meter should then read 1888 To protect the LEDs the test function should only be used for 10 seconds maximum 2012 DynAmp LLC Page 21 041663 J Installation Operation and Service Manual COP D DC and COP D RMS VOLTAGE SOURCE BATTERY SUPPLY 1950 4 8 8 0V Hi Lo CONNECTOR DIGITAL PANEL METER Figure 8 3 Panel Meter Test Circuit 2012 DynAmp
7. DynAmp MODEL COP D DC and COP D RMS PORTABLE DC amp RMS CURRENT METERING Installation Operation and Service Manual Manual Item No 041663 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 help adynamp com Installation Operation and Service Manual COP D DC and COP D RMS This Page is Intentionally Blank 2012 DynAmp LLC Page ii 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 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
8. In no event shall DynAmp LLC be liable for consequential damages Information in this document is subject to change without notice 1999 2000 2001 2002 2004 2010 2012 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 2012 DynAmp LLC Page iii 041663 J Installation Operation and Service Manual COP D DC and COP D RMS This Page is Intentionally Blank 2012 DynAmp LLC Page iv 041663 J Installation Operation and Service Manual COP D DC and COP D RMS Hazard Warning 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 customers failure to comply with the rules and requirements provided in this manual GENERAL This equipment is designed for use where the operator is
9. Installation Operation and Service Manual COP D DC and COP D RMS TABLE OF CONTENTS 1 SAFETY 1 Tali OW ER WIE nartinlensee 2 HANDLING AND STORAGE 1 3 DESCRIPTION 3 GENERALE a shaven aa terddely 3 32 METER UNI Torentai aa 3 3 3 MEASURING HEAD etaa a 4 4 SPECIFICATIONS 5 5 ENVIRONMENTAL AND SPECIAL CONSIDERATIONS 7 Ds a 7 5 2 ea aa 7 Bia cos das 7 E eae 7 6 CONTROLS AND PRINCIPALS OF OPERATION 9 6 1 CONTROLS AND INDICATORS wgseassaxs cscschinsa istnesvia a ta boueiivi ante bastante a tacaatixea st 9 6 2 OPERATION irae tra dace cat ius 10 6 3 USING DIGITAL ceratesabetveusnaabhacseaabsanseasbuacsees 11 6 4 REMOVING INSTALLING 12 6 5 CHARGING BATTERIES srw REEE AORE a a caleceburane
10. LLC Page 22 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 9 SERVICE ASSISTANCE 9 1 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 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 9 2 SPARE PARTS ORDERS ROUTINE OR EMERGENCY Requests for spare parts either in an emergency or for a routine order should be directed to Inside Sales at DynAmp LLC during normal hours if possible or via any method shown above for off hours When contacting us please present as much information as possible the related equipment Model Number and Serial Number the required part name and its DynAmp LLC
11. Momentarily holding the switch toggle left or right resets the digital readout to zero Digital Readout The LED display reads from 0 000 to 1 999 for the 2kA range and from 0 00 to 19 99 for the 20kA range regardless of polarity This display will include a sign to the left of the numerals when the measurement is negative The model COP D RMS will always read positive The polarity of the readout is dependent on the orientation of the measuring head when clamped around the bus and will be positive no sign if the red dot on the head faces the positive bus supply source 1 LOW and 2 LOW Indicators LED s These indicate a low battery condition if illuminated when the FUNCTION SELECTOR switch is in the BATTERY TEST position ALTERNATE BATTERIES Switch On battery pack Reverses the uneven load arrangement on the two batteries in the pack to obtain maximum use before recharging is required ANALOG OUTPUT Optional An analog output of 200V at full scale is available at terminals 1 amp 2 and 3 amp 4 of the output connector on the right side of the unit 2012 DynAmp LLC Page 9 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 6 2 OPERATION The procedure for proper setup and operation of the COP D Digital Ammeter is as follows a Clip the carrying strap to the meter One strap or both straps may be used Figure 6 1 illustrates how both are used to provide the most comfort
12. ability and rechargeable batteries are prominent features A variety of choices in clamp on measuring head styles sizes and handle lengths permits matching the COP D meter and head combination to meet the desired measurement requirements Each Model COP D consists of the following components e Measuring head e Meter unit e Rechargeable battery pack e Two carrying straps e Battery charger The battery pack plugs into and fastens to the rear of the meter unit to make an integral assembly The carrying straps clip to rings on the meter unit The measuring head has a coiled cable which plugs into a mating connector on the meter unit The battery charger plugs directly into a conventional 120 Vac 50 60 Hz outlet and has a 3 foot cable and connector for plug in to the battery pack The battery pack provides approximately 20 to 24 hours of meter use and may be recharged either on or off the meter unit For safety considerations the meter unit is not intended to be operational during recharging A spare battery pack if included ensures that the meter will be available for use at all times 3 2 METER UNIT The Meter Unit has two measurement ranges 0 to 2kA and 0 to 20 or 0 to 10kA and 0 to 100kA and utilizes a digital readout An extremely sensitive integrator circuit provides the high measurement accuracy of the unit The digital readout permits resolutions of up to 1 ampere and 10 amperes on the 2kA and 20 ranges respective
13. d Service Manual COP D DC and COP D RMS 4 SPECIFICATIONS The specifications of the COP D DC and COP D RMS are given in table 4 1 TABLE 4 1 SPECIFICATIONS Measurement ranges 0 to 2kA digital readout to 1 999 0 to 20kA digital readout to 19 99 or 0 to 10kA digital readout to 10 00 O to 100kA digital readout to 100 0 Analog output See Note 1 2 000V at full scale Overall accuracy 2 5 of full scale model COP D DC 3 0 of full scale model COP D RMS Linearity error max 1 0 of full scale model COP D DC 3 0 of full scale model COP D RMS for sine wave Position error max Variation in position of measuring head relative to bus yields maximum error of 1 5 of full scale Stray field error max An identical bus and field 6 inches away yields error of less than 1 5 of full scale Drift rate error Within a 30 second interval after routine drift adjustment maximum error due to drift will be 1 0 of full scale 2012 DynAmp LLC Page 5 041663 J Installation Operation and Service Manual COP D DC and COP D RMS TABLE 4 1 SPECIFICATIONS CONT 4 F to 130 F 20 C to 55 C Isolation System Meter unit weight with battery 4 5 Ibs Measuring head Measurement range max kA See Note 3 Aperture dimensions in Consult factory Handle length in Consult factory Cable length in 72 Weight pounds Varies with head Note 1 Optional output
14. d momentarily operate RESET switch to zero output Adjust the test bus current source to obtain a bus current of 1000 amperes With measuring head closed and NOT on the bus operate RESET Place the head around the bus close and note meter unit readout 1 If the readout is 1 000 0 005 proceed to step q 2 If the readout is not within limits adjust P2 as required to obtain a readout of 1 000 0 005 The current must be stable at 1000 amperes during this adjustment If the adjustment is made satisfactorily proceed to step s If adjustment of P2 will not bring the readout up to 1 000 proceed to step o Remove the head from the test bus and close Turn COARSE adjustment P3 approximately 5 turns CCW Operate RESET then again place head around test bus The reading should be somewhat higher than obtained in step l 2 Repeat steps m and n until a readout of approximately 1 100 or 10 greater than the bus current is obtained Note when the head is on the test bus it is not possible to change the readout by adjustment of P3 With the reading high as established in steps m through readjust P2 to obtain a readout of 1 000 0 005 This completes calibration of the 2kA range 2012 DynAmp LLC Page 16 041663 J Installation Operation and Service Manual COP D DC and COP D RMS For the 20kA range calibration a test bus current of 10 000 amperes is preferred but other levels can be used if necessary In the following a c
15. destsaneacbantiecestes 12 60 0 SPARE BATTERY en ara a a a eee 12 7 CALIBRATION 13 TEV GENERA 13 7 2 CALIBRATION INTERVALS i jiaseiccatdcn 19 7 3 GALIBRA TION BUS veiticec aie 13 TA TEST BUS FABRICATION n A ene 14 7 0 CALIBRATION PROCEDURE CLa a RAS onde ee 14 8 TROUBLESHOOTING AND REPAIR 19 81 GENERA rarr eee eed Se aed 19 8 2 MEASURING aie iaiia 19 8 3 BATTERY PACK AND CHARGER 00 ccceeeeeceeeeeeeeeeeeeeeeaaaeeaeeeeeeeeeeaaeeeeeeeeeeeaaeaneees 19 8 4 METER 20 9 51 wonton Garni oi athe nn oars 21 2012 DynAmp LLC Page xi 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 9 SERVICE ASSISTANCE 23 9 2 SPARE PARTS 5 23 9 3 RECOMMENDED cove etsertedete dvds atided desk phe 24 10 DRAWINGS 25 TABLE OF FIGURES AND TABLES FIGURE TITLE PAGE Figure 6 1 Proper wear of the COP D
16. e turn DRIFT ADJUST in a CW direction if readout is becoming less positive or going more negative turn DRIFT ADJUST in the CCW direction Continue adjustment until readout rate of change slows and is eventually stopped at any given value except 1999 NOTE The model COP D RMS will not respond in this manner CW or CCW movement will not necessarily correspond to a meter direction of plus or minus respectively 6 Tighten DRIFT ADJUST lock ring observing that adjustment is not changed 7 Operate RESET to zero readout e Turn FUNCTION SELECTOR to desired measurement range 2kA or 20kA or 10 or 100 f With measuring head closed and off the bus operate RESET to zero readout just prior to making measurement Open the measuring head and place it around the bus Close the measuring head and promptly note value and polarity of readout When the measuring head is placed around the bus such that the red dot faces the positive bus supply source the reading will be positive If the sign is on it is not necessary to take another reading with the measuring head reversed The readout valued will be identical in either case See Using Digital Readout below for additional details on measurement technique g ensure maximum accuracy zero the readout with the RESET switch before each measurement This should always be done with the head completely closed and off the bus It is not necessary to reset the meter for each measure
17. facility it is recommended that the meter and measuring head be returned to the factory for calibration once it has been suspected or known that measurement accuracy is not within limits However accurate calibration results can be achieved by the user if the following conditions and procedures can be met 7 2 CALIBRATION 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 e Requirements of a Quality Management System e Accuracy and permissible limits of errors e Purpose and usage e Experience with similar products e Manufacturer s recommendations e Stability of the product e Past history e 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 7 3 CALIBRATION BUS An actual bus can be used as the calibration standard providing 1 that the current is accurately known 2 the current level is very stable and 3 the a
18. fied technician who is familiar with the warnings and the instructions of this manual Always follow all local and plant safety procedures Hazardous potentials may exist in the vicinity of the desired current measurements Use locally approved safety procedures when working near these hazardous potentials Always use appropriate gloves and or equipment specifically approved for hazardous voltages when working around hazardous potentials Do not place the equipment in the rain or under water or submerge any part of the head or meter unit Use of the equipment in a manner not specified by the manufacturer can impair the protection provided DynAmp does not assume liability for the customer s failure to comply with the rules and requirements provided in this manual 2012 DynAmp LLC Page 1 041663 J Installation Operation and Service Manual COP D DC and COP D RMS This Page is Intentionally Blank 2012 DynAmp LLC Page 2 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 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
19. ge continuity or resistance checks as appropriate If unable to isolate the trouble or to make repairs return all components to DynAmp LLC to ensure thorough checkout and proper recalibration with the measuring head supplied IMPORTANT NOTE The COP printed circuit board is a sensitive instrument and was factory cleaned as to avoid any surface contaminants that may lead to circuit drift and or circuit inaccuracy If soldering needs to be done use only solder containing rosin core flux The board should only be cleaned with a cleaner such as Sonic Solve or Trichloroethane to be effective BE SURE TO READ ALL SAFETY RECOMMENDATIONS CONCERNING THE USE OF THESE SOLVENTS BEFORE PROCEEDING WITH THE P C B CLEANING If repairs to the meter unit are made which involve replacement of the operational amplifier RMS converter related potentiometers and resistors or if the adjustment of any of P1 thru P4 is changed the meter unit must be recalibrated Refer to Controls and Principals of Operation section in this manual 2012 DynAmp LLC Page 20 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 8 5 DIGITAL PANEL METER The Digital Panel Meter can be checked using the following information a f Disconnect the digital meter by unplugging it from the connector mounted on it s rear Using a different connector or separate wiring connect pin 12 to pin 3 of the meter Also connect pins 7 and 8
20. ge 15 Installation Operation and Service Manual COP D DC and COP D RMS To calibrate the meter unit proceed as follows NOTE The following steps make reference to circuit common Use the proper end of resistor R24 for this point Refer to the p c board schematic and assembly diagrams a b Remove the battery pack from the rear of the meter unit Remove the back plate of the meter unit four flat head screws Reconnect the back plate to the battery pack Sufficient lead length is available to do this With the measuring head connected to the meter unit set the FUNCTION SELECTOR switch to BATTERY TEST If either LOW lamp is on recharge the battery pack If both lamps are off continue with step f Turn the FUNCTION SELECTOR to DRIFT and adjust for minimum drift as described in Section IV Controls and Principals Of Operation Attach a dc millivolt meter to the output of U1 pin 6 to circuit common Hold the RESET switch closed Adjust P4 for the best zero reading Remove meter If U2 is not installed go to the next step Again hold the reset switch closed while adjusting P5 for the best zero reading on the COP meter face If U3 is not installed go to the next step Attach the dc millivolt meter to the output connector pin 1 to pin 4 Again hold the reset switch closed while adjusting P6 for the best zero reading Remove meter Recheck drift adjustment step f Turn FUNCTION SELECTOR to the 2kA range an
21. iagram Assuming battery voltages were low check outputs of charger to be 6 7 0 5 V dc at the pins of the connector on the output cable see figure 8 2 If charger is faulty refer to schematic and PCB layout in this manual to initiate repairs or return the charger to the factory 2012 DynAmp LLC Page 19 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 6 0 5V 6 7 0 5V Ro 4 O 5 2 Ny W Figure 8 2 Charger Cable Connector Wiring Diagram Assuming battery voltages were low and charger outputs were satisfactory recharge the battery pack for at least 8 hours and recheck outputs Note a fully discharged battery pack can take a considerable period of time to recharge If outputs have increased but are still low continue charging A zero output of a battery will usually indicate faulty internal wiring or a faulty ALTERNATE switch If after charging the output voltages measure satisfactory with no load but are low or rapidly dropping when loaded BATTERY TEST position then it may be time to replace the batteries The batteries have a lifetime expectancy of 200 to 500 charge discharge cycles 8 4 METER UNIT When reasonably sure that the measuring head and battery pack or charger are not the source of trouble proceed with troubleshooting of the meter unit Due to the simplicity of the unit no explicit procedures are given Study the schematic and proceed from the input making volta
22. item number and other identifying or vendor number s and your time needs An approved Purchase Order Number should be given with your order 2012 DynAmp LLC Page 23 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 9 3 RECOMMENDED SPARE PARTS Table 9 1 lists the minimum recommended quantities for spare parts for the COP D DC and COP D RMS As spares are used replacements should be ordered Since continuous operation of high current measurement equipment is usually essential stocking spare parts should be given a high priority TABLE 9 1 SPARE PARTS LIST DESCRIPTION ITEM NO QUAN Measuring Head Bracket reinforcing 01033 1 Spring 2 8 01781 1 Cable 02119 1 Cable strain relief 02819 1 Bracket reinforcing part line 02932 1 Cable connector 03282 1 3 Straight module not used with the 5 x 5 head 04239 2 Corner module 04240 2 Metering Unit Pot 50k ohms 10T 001085 1 Cable connector 003398 1 Function switch assembly 004864 1 Reset switch 007733 1 OP Amp OP 77 024316 1 P C Board assembly 041023 1 Meter 041603 1 2012 DynAmp LLC Page 24 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 10 DRAWINGS The following is a list of drawings needed to troubleshoot and calibrate the COP D DC and COP D RMS metering units TABLE 10 1 DRAWING LIST DRAWING TITLE NUMBER Outline Dimension
23. le if during observation the changing readout shows 1 529 1 539 1 54 1 55 1 54 1 539 1 589 1 529 1 599 the measured value should be recorded as 1 530kA A relatively stable current will thus 2012 DynAmp LLC Page 11 041663 J Installation Operation and Service Manual COP D DC and COP D RMS usually be readable within 10 amperes on the 2kA range and 100 amperes on the 20kA range A constantly changing current can also be monitored with reasonable accuracy by observing just the ABC digits where the readout is A BCD or AB CD and D is changing too fast to read If the C digit is also changing too fast to read the A and B digits will still provide sufficient information to monitor approximate current value and direction and rate of change The length of time and degree of change to be observed will be up to the operator to determine 6 4 REMOVING INSTALLING BATTERY PACK Electrical connection of the battery pack to the metering unit is made by fixed mating connectors on each unit The pack is secured by two lever action fasteners on the metering unit To remove the pack release both fasteners and then gently work the pack connector free of the metering connector Reverse the procedure to install the pack using care to properly mate the connectors and the side fasteners 6 5 CHARGING BATTERIES Connect the battery charger output cable connector to the mating connector on the rear of the battery pack Plug the charge
24. ly Due to the sensitivity of the integrator circuit an external DRIFT ADJUST control is incorporated to immediately compensate for any factors such as ambient temperature changes that may affect the readout The model COP D RMS can be used to read dc as well as ac rms signals There is one thing to keep in mind when using this model for measuring dc The reading indicated will not be dc average as in the COP D DC but it will be the rms value of the dc plus ac components of the measured current 2012 DynAmp LLC Page 3 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 3 3 MEASURING HEAD The measuring heads are constructed from high impact high temperature non conducting molding compound The standard heads are available in many sizes of rectangles They range from a 5 x 5 inch inside dimension to a 17 x 17 inch inside dimension The X and the Y dimensions may be vastly different depending upon the size of your bus to be measured Consult the DynAmp LLC factory as to the specific dimensions of standard heads The head handles are available in 2 4 and 6 foot lengths for all standard heads The measuring heads are also available without handles To ensure long and useful operation Do not rub the measuring head against sharp or abrasive objects e Close clamping jaws gently Donot drop or jar the head assembly or metering chassis 2012 DynAmp LLC Page 4 041663 J Installation Operation an
25. ment providing the drift rate is well adjusted h During a series of measurements periodically check for drift of the readout just after RESET When the rate of change of the least significant right hand digit is more than one unit per second repeat the drift adjust procedure in step d i During continuous use recheck the batteries about once per hour particularly if the charge status of the battery pack is unknown j Turn the FUNCTION SELECTOR switch to OFF to conserve battery power when the meter is not going to be used for 15 20 minutes or longer when the meter is being stored or when the battery pack on the meter is being recharged 6 3 USING DIGITAL READOUT Due to the high resolution of the digital readout very small percentage changes in bus current will cause the least significant digit to change so rapidly that it cannot be read This condition may frequently occur and should not be confused with excessive drift Also the condition does not significantly affect accuracy For example when in the 2kA range disregarding the right hand digit and using only the three readable left hand digits resolution will be within 10 amperes Example for 1 532 this reading yields a 0 65 accuracy The same accuracy would be obtained for a reading of 15 3 on the 20kA range However to achieve this accuracy it may be necessary to observe the readout for several seconds to determine which tens digit is predominant For examp
26. n 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 60 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 2012 DynAmp LLC Page 1 041663 J Installation Operation and Service Manual COP D DC and COP D RMS This Page is Intentionally Blank 2012 DynAmp LLC Page 2 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 3 DESCRIPTION 3 1 GENERAL The DynAmp LLC Model COP D Digital Ammeter provides a clamp on non contacting dc current or dc coupled rms measuring capability includes ac rms Ranges are 0 to 2kA 0 to 20kA and 0 to 10kA 0 to 100kA The dc version is model COP D DC item number 041601 for 20kA F S and number 041603 for 100kA F S and the ac rms version is model COP D RMS item number 041602 for 20kA F S and number 041604 for 100kA F S This manual also refers to a COP D 2 to 20kA that has an analog output item number 041605 The COP system item given only refers to the 120Vac model Digital readout lightweight easy port
27. r directly into a conventional 120 V ac 50 60 Hz outlet Recharge battery pack 3 to 4 hours if low batteries are routinely detected by the battery test Recharge 6 to 8 hours if the batteries are completely discharged Completely discharged batteries will be indicated by the following LOW lights do not come on during battery test Digital readout does not illuminate when the FUNCTION SELECTOR switch is in DRIFT 2kA or 20 or 10kA or 100kA positions Note The battery charger design prevents overcharging of the batteries If the unit is used almost daily then it is recommended the unit be continuously charged when not in use Charging may be continuous without damage to the charger or battery pack The battery pack may be charged either on or off of the metering unit If left on the metering unit the FUNCTION SELECTOR should normally be OFF during recharging 6 6 SPARE BATTERY PACK Use of a spare battery pack is recommended to ensure that the meter unit is always available for use The recommended procedure is to recharge one pack during the time the other pack and the metering unit are in use After use of the meter is completed interchange the two packs Repeat this process for each shift that the meter is used 2012 DynAmp LLC Page 12 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 7 CALIBRATION 7 1 GENERAL Due to the strict requirements for a proper calibration setup in the user s
28. rea where the calibration is done is free of stray magnetic fields of significant magnitude or varying intensity Also for best results a current level in the range of 60 to 95 of full scale current should be used for calibrating the COP meter unit on each current range 95 would be best Lacking availability of the bus in an area free of stray fields a test bus can be fabricated as described in this section Use of a fabricated test bus will also require an accurately metered and adjustable constant voltage variable current dc power source For the test bus described herein the power source rating should be one of the following 150 V dc 0 to 10 A 80 V dc 0 to 20 A or 40 V dc 0 to 40 A Sources with other ratings can be used but will require a test bus design different than described 2012 DynAmp LLC Page 13 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 7 4 TEST BUS FABRICATION Refer to Figure 7 1 to make up the test bus Approximately 6200 feet of copper magnet wire will be required The method used to connect the four coils will depend on the rating of the power source available As stated before other designs may be used so long as the total current can be calculated and controlled 7 5 CALIBRATION PROCEDURE The following procedure assumes use of the fabricated test bus bus currents of 1000 and 10 000 amperes and you are calibrating a 2 20kA meter unit Change test stated values in
29. rger or the metering unit Repair if indicated should be accomplished by a qualified technician or at the DynAmp LLC factory 8 2 MEASURING HEAD Internal failure of the measuring head is a remote possibility but should not be disregarded Failure within the interconnecting cable or connector is a more probable trouble source Resistance measurements taken at the pins of the connector cable within the values listed below will confirm that the cable conductors and the series connected coils in the measuring head are not open or short circuited Tap the head firmly and shake the cable when measuring to check for the possibility of an intermittent fault If the measurement is obviously in error return the measuring head and meter unit to the factory for repair and recalibration SERIES RESISTANCE OHMS STANDARD MODELS all sizes 20 000 2000 8 3 BATTERY PACK AND CHARGER To check for a battery pack fault measure both outputs at the rear connector terminals see figure 8 1 The outputs should be 6 1 V dc or higher with the battery pack off the meter unit With the battery pack on the meter unit and the FUNCTION SELECTOR at BATTERY TEST both outputs should be 5 3 V dc or higher If the readings are low either recharging is required the battery charger is faulty or the battery pack is faulty If all readings are satisfactory check out the meter unit 6 7 O 5V 6 7 O 5V gt is Figure 8 1 Battery Pack Connector Wiring D
30. rvice 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 2012 DynAmp LLC Page vii 041663 J Installation Operation and Service Manual COP D DC and COP D RMS This Page is Intentionally Blank 2012 DynAmp LLC Page viii 041663 J Installation Operation and Service Manual COP D DC and COP D RMS REVISION PAGE Page Rev Revision Summary Date all New First Issue 03 97 2 3 4 RevA Added voltage isolation amp temp spec 08 97 25 26 Rev B Spare Parts List 08 97 iii 1 7 Rev C Inserted Hazard Warning page and Safety Section 09 99 27 Rev D Revise Spare Parts List Reset Switch 09 99 i 25 Rev E Warranty statement amp Communications 02 00 all Rev F Updated to current format 03 01 Updated drawing list removed 26B100527 and 25 Rev G replace with 26B107083 06 02 all Rev H Update to DynAmp LLC 12 04 PAR 10245 Handling amp Storage ECR 1440 all Rev Calibration Intervals New Manual Format 01 10 ECO 3270 Update Drawing List removed 26B107083 25 Rev J replace with 26A109281 04 12 2012 DynAmp LLC Page ix 041663 J Installation Operation and Service Manual COP D DC and COP D RMS This Page is Intentionally Blank 2012 DynAmp LLC Page x 041663 J
31. s Digital COP Metering Unit 02A109158 System Schematic Digital COP and Battery Charger 05B108015 PC Board Assembly Digital COP 26B107804 PC Board Assembly Battery Charger 26A109281 PC Board Assembly Digital COP Meter Interface 26A108014 2012 DynAmp LLC Page 25 041663 J
32. s manual AFETY The Model COP System is intended for use where the operator is either totally electrically isolated or essentially at the same potential as the bus Ignoring the operating precautions and warnings can result in severe personal injury or equipment damage 2012 DynAmp LLC Page 7 041663 J Installation Operation and Service Manual COP D DC and COP D RMS This Page is Intentionally Blank 2012 DynAmp LLC Page 8 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 6 CONTROLS and PRINCIPALS OF OPERATION 6 1 CONTROLS AND INDICATORS All controls and indicators described are on the meter unit unless stated otherwise 1 DRIFT ADJUST Control This 10 turn potentiometer is used to stabilize drifting of the digital readout The control LOCK ring must be unlocked to adjust the knob and relocked after adjustment FUNCTION SELECTOR Switch The OFF position disconnects all circuitry from the batteries and should be used when the meter is stored or when not in use for 15 20 minutes or longer The BATTERY TEST position provides a check of battery condition as indicated by LOW lights DRIFT position is used in conjunction with DRIFT ADJUST to stabilize any drifting of the digital readout The 2kA and 20kA or 10kA and 100kA positions are the full scale ranges for measurement of bus current RESET Toggle Switch The RESET switch is spring loaded to the center inactive position
33. the procedure where appropriate for other bus current values and meter units Note Calibrations should be conducted in an area as free as possible from stray magnetic fields for best accuracy Medium to strong fields or fields of varying intensity can prevent proper calibration LEADS STEP 1 Make 4 coils 250 turns each from No 14 AWG enameled copper magnet wire tightly wound on 18 square form Remove from form and tape windings as shown Allow about 1550 feet of wire per coil Resistance of each coil will be approximately 3 75 ohms TYPICAL COIL fig Figure 7 1 Typical Test Coil 2012 DynAmp LLC Page 14 041663 J Installation Operation and Service Manual COP D DC and COP D RMS TAPE STEP 2 Assemble coils as shown and tape common sides together The common side of the assembly is the bus around which the measuring head is placed for calibration Set assembly on non conducting surface for operation Figure 7 2 Test Coil Assembly STEP 3 Depending on the dc power source available connect the coils in series A series parallel B or parallel C Refer to the coil diagrams below 150V 0 10A 80V 0 20 R 3 765 OHMS 500T x 10A x 2 10 000AT Max R 0 94 OHMS 250T x 10A x 4 10 000AT Max Figure 7 3 Test Coil Circuit Diagram 2012 DynAmp LLC 041663 J Pa
34. urrent of 10 000 amperes is assumed with a desired meter readout of 10 00 With the head OFF of the bus and closed turn FUNCTION SELECTOR switch to the 20kA range and operate RESET to zero readout If any drift of readout is evident stabilize with DRIFT ADJUST in the usual manner Adjust the test bus current source to obtain a bus current of 10 000 amperes With the measuring head closed and NOT on the bus operate RESET Place the head around the bus close and note meter readout 1 If the readout is 10 00 0 05 calibration is satisfactory 2 If the readout is not within limits adjust P1 as required to obtain a readout of 10 00 0 05 The current must be stable at 10 000 amperes during this adjustment Do not make any change in the adjustment of P3 since it affects both ranges and has already been properly adjusted When P1 is satisfactorily adjusted calibration is complete x Replace meter unit back plate and then replace battery pack Meter is now ready for normal use Turn meter OFF and disassemble the test setup 2012 DynAmp LLC Page 17 041663 J Installation Operation and Service Manual COP D DC and COP D RMS This Page is Intentionally Blank 2012 DynAmp LLC Page 18 041663 J Installation Operation and Service Manual COP D DC and COP D RMS 8 TROUBLESHOOTING AND REPAIR 8 1 GENERAL Troubleshooting should begin by isolating the problem to either the measuring head the battery pack or cha
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