iSAVER DPFC 165 & 250 Series ‘The Eliminator’

OPERATING MANUAL iSAVER DPFC 165 & 250 Series

‘The Eliminator’

– Page 2 –iSaver DPFC 165 & 250 Series Manual © 2021 Encorp Limited

TABLE OF CONTENTS

Section 1 Introduction 3

Section 2 Specifications 6

Section 3 Installation 9

Section 4 Start-up 11

Section 5 Periodic Maintenance 25

Section 6 Troubleshooting 26

Section 7 Limited Warranty 32


1.Introduction

iSaver ManualThis manual is intended as a general guide for the installation, commissioning, maintenance, and troubleshooting of iSaver DPFC (Dynamic Power Factor Control) units.

This manual is written for qualified and licensed personnel exclusively. It is not a substitute for professional training, safety and hazard procedures, or for handling industrial equipment. This equipment must be installed as per applicable Canadian standards, Regulations and National wiring rules. This is essential to avoid electric shock or fire resulting in personal injury and damage to equipment. Improper connection, handling, or installation may cause malfunction and potential damage.

After going through the contents of this manual, if there are any doubts with regard to connectivity, commissioning, operation or any other subject, it should be clarified with the authorized representative of the supplier. Encorp does not accept any responsibility for any damage (direct or indirect, consequential loss) incurred due to improper installation or use of this unit(s).

Special PrecautionsThe following are mandatory safety measures when installing or using iSaver equipment:

• Measure the electrical parameters to ensure that the unit selected is appropriately sized and suitable.

• The standard iSaver units are designed for indoor use only and should be installed in a secure, dry environment.

• During transportation from the manufacturing unit to the customer’s premises, there is always a chance of some connections within the unit becoming loose. It is mandatory to internally inspect the unit and tighten any loose connections prior to installation and start-up.

• Depending on the environment and site conditions, the unit should be periodically inspected internally by a qualified electrical technician.

Introduction Majority of the loads in commercial establishments & industrial processes have very rapidly changing loads due to the nature of their operation. These are usually complex loads highly inductive in nature as they use induction motor drives, AC/DC drives, Arc Furnaces, Welders, CNC machines, Sodium Vapor / Metal Halide / Fluorescent lighting etc.

Though there are also some resistive and potentially some capacitive loads, the overall nature of this electrical load is complex inductive load. This complex inductive load causes a poor lagging power factor. If this poor power factor is left uncorrected, it draws excessive current (kVA) than the required amount to perform useful work. As Utilities have to provide for the high demand which also effects their operations and distribution, they usually impose one or several charges if the electrical efficiency of the end user is lower than their contracted value. Depending on the tariff structure of the individual, this may increase their electricity bill and reduce available capacity substantially. As a consequence of low efficiency, the customer may get charged for high demand offtake, reactive power charges, power factor penalties etc. The increased current due to low efficiency also effects the installed capacity utilization of the facility.

Using iSaver DPFC (Dynamic Power Factor Corrector), electrical efficiency is enhanced almost to 100% and consequently the monthly Electricity bill* is substantially reduced.


iSaver DPFC is fully automatic and based on the load requirement improves the power factor in real time to near unity value which will result in a justified Return on Investment (ROI). In addition, it enables release of wasted capacity of installed switch gear voltage fluctuations due to high kVA draw, lowers heating of switch gear transformers and local network. iSaver technology also compliments environmental sustainability by improving higher efficiency.

* subject to customer tariff structure

Features• Your iSAVER uses a fully automatic Dynamic Controller (micro controller based Reactive Power regulator) for

accurate 4 Quadrant measurements that enable precise efficiency enhancement.

• Software based logic driven for efficient selection of required compensation for fast and efficient operation.

• Control is dynamic and follows the load fluctuations without any delay.

• Constant check and display of parameters on display panel. Display of key parameters like Voltage, Current, kVA, PF enables end users, to utilize installed switch gear with higher efficiency.

• Self-diagnostic feature enables on-line equipment performance verification which is extremely useful for installation and maintenance.

• Built in a strong Floor mounted, powder coated finish to RAL 7035 with lockable secure enclosure.

• Equipment and components used are of high quality with conservative design parameters to increase longevity of equipment.

• The internal design is fully accessible, and inspection/checks and any routine maintenance are logical and easy.

• Extremely easy to install with its own multi-indicator & practically no maintenance requirement. The Power and Energy meter enable monitoring of actual consumption and other parameters.

• Short circuit and overload protection provided through MCB or MCCB.

• Over temperature protection is provided by shutting downing the Dynamic Switching (EDS) to provide complete safety.

• Your iSAVER cooling and ventilation system is operated automatically only when required, minimizing the units power consumption and power footprint.

• High Voltage Surge protection provided.

• Remote web based on-line performance monitoring option also available.

Benefits• Total Power bill is reduced and installed power capacity improved based on the site operating conditions.

• Demand Charge and Power Factor penalty charges (additional charges) imposed by the Power Utility for low efficiency are significantly reduced.

• Wastage and switch gear overburden caused by low efficiency and harmonics causing heating losses are substantially reduced.

• Load utilization capability of the facility is improved. Release of installed capacity can be as much as 25-35% and helps avoid costly upgrades.

• Carbon footprint is reduced contributing to improved environmental sustain ability.

• Reduces total connected total power (kVA) requirement from utility. This results in cost avoidance for upgrades and

availability of additional power is almost instantaneous.

• The web-based performance monitoring feature of iSAVER enables online viewing and is useful to monitor the end users load and any abnormal/faulty conditions remotely.


ApplicationIndustries and commercial establishments with rapidly changing fluctuating motorized equipment. Such examples are:

• AC/DC drives, Arc Furnaces, Welders, CNC machines, etc.

• Machine shops / Industrial manufacturing & Processing/ induction furnaces, etc.

• Multi-elevator systems, Escalators, CT scanners, MRI machines etc.

Selection of EquipmentiSaver DPFC Units are to be used in applications where the electrical loads are highly fluctuating at very short intervals. In such applications, the reactive power demand is almost instantaneous and the iSaver-DPFC is designed to compensate within few milliseconds that requirement and maintain the Power Factor close to unity.

To select the correct size of iSaver DPFC, it is a good practice to measure the maximum reactive power requirement as well as Voltage and Current Harmonics so that the correct size of equipment can be selected. It is envisaged that a qualified and experienced professional will be consulted to assist in the selection process.

iSaver DPFC is designed to dynamically compensate that reactive power requirement in real time, reduce harmonics significantly and maintain the power quality with Power Factor close to unity.


2.Specifications

Standard Specification for iSaver 160A

Model iSAVER-160A-3Ph

Voltage Input 600 VAC 60Hz

Supply Three Phase

Configuration 3 Phase – 4 Wire or 3 Wire

Current Rating 160A Nominal (165 kVAR)

Banks 1x27.5 + 1 x 55+ 1x82.5 kVAR

Minimum Correction Bank activation at Reactive load >19.5 kVAR

Sequence 1:2:3:3:3

Electrical Steps 06

Logic The unit is designed to operate in steps of 27.5 kVAR

Minimum Step 70% of the lowest Bank Capacity (19.5 kVAR)

Control Operation Controlled real time switching output based on load requirements.

Controller Micro controller based advanced electronic controller

Target Efficiency > 98% (+/- 3%)

Energy Monitoring HMI Module with IP controller board

Displayed Data (RMS) V, I, kVA, kW, Hz, kWh, PF, kVAR, Hz, KVARh saved kVAh lag,THDv,THDi, Deg. F

Display Meter Zero Voltage/current, Over Voltage/current, Over Under compensation Under Volt, Excess VTHD & ITHD, iSAVER UNB Current

Diagnostics Phase & CT Sequence Indicator

Bank Protection Short circuit and Over-load protection (MCCB & MCB)

Construction Robust standalone metal enclosure (indoor application only)

Dimensions 1300 (H) x 1000 (W) x 750 (D)

Weight 375Kg

Mounting Floor Mounting with Foundation Bolts

Enclosure Powder coated corrosion resistant sheet steel enclosure (RAL 7035)

Transient protection Provided

Cable Entry Bottom and Right-side entry provision.


Standard Specification for iSaver 240A

Model iSAVER-240A-3Ph

Voltage Input 600 VAC 60Hz

Supply Three Phase

Configuration 3 Phase – 4 Wire or 3 Wire

Current Rating 240A Nominal (247.5 kVAR)

Banks 1x27.5 + 1 x 55+ 2x82.5 kVAR

Minimum Correction Bank activation at Reactive load >19.5 kVAR

Sequence 1:2:3:3:3

Electrical Steps 09

Logic The unit is designed to operate in steps of 27.5 kVAR

Minimum Step 70% of the lowest Bank Capacity (19.5 kVAR)

Control Operation Controlled real time switching output based on load requirements.

Controller Micro controller based advanced electronic controller

Target Efficiency > 98% (+/- 3%)

Energy Monitoring HMI Module with IP controller board

Displayed Data (RMS) V, I, kVA, kW, Hz, kWh, PF, kVAR, Hz, KVARh saved kVAh lag,THDv, THDi, Deg. F

Display Meter Zero Voltage/current, Over Voltage/current, Over Under compensation Under Volt, Excess VTHD & ITHD, iSAVER UNB Current

Diagnostics Phase & CT Sequence Indicator Short circuit and Over-load protection (MCCB & MCB)

Bank Protection Short circuit and Over-load protection (MCCB & MCB)

Construction Robust standalone metal enclosure (indoor application only)

Dimensions 1600 (H) x 1100 (W) x 750 (D)

Weight 475Kg

Mounting Floor Mounting with Foundation Bolts

Enclosure Powder coated corrosion resistant sheet steel enclosure (RAL 7035)

Transient protection Provided

Cable Entry Bottom and Right-side entry provision.


Suggested Connection Cable Size*

iSAVER Rating Rating of Main Incoming Breaker

Suggested* Minimum Cable rating (3.5 core)

Suggested* Cable Rating (GND & Neutral)

iSAVER- 160AiSAVER- 240A

250A500A

212 KCmil Copper Cable400 KCmil Copper Cable

Per regulatory requirements

* Based on maximum current rating of the iSAVER incoming breakers


3.Installation

Step by Step Connection

• This equipment must only be installed and serviced by qualified electrical personnel.

• Place the iSAVER rigidly in a secure, dry, suitable environment as close to the distribution panel as possible with sufficient space to connect the terminal section.

• Open the front and back panel door and visually inspect to ensure that nothing has become loose during transportation and handling. If there is any evidence of damage or loose wires, repair or replace prior to proceeding further.

• Select side or bottom entry terminal entry gland plates based on model and site requirement and disassemble the selected gland plate by removing fasteners.

• Drill appropriate size hole for Cable entry and use suitable sized rubber Gourmet to ensure adequate safety of cable insulation as well as to avoid entry of unwanted pests.

• All cables to the iSAVER should be routed through the rubber gourmet and the gland reinstalled.

• Turn down the power from the main power supply to the facility and ensure it is not energized and safe to connect.

• Ensure the main breaker of the distribution board and iSAVER breakers are in an ‘OFF’ position.

• Select approved CT size based on the capacity of the Main Power supply breaker of the site. (Ex. If the breaker size is 1250A, the CT to be used should also be rated as 1250/5 Amps, 600V AC). In some situations, the physical installation clearance and bus bar size will determine the internal diameter of the CT coil to be used.

• The CT’s must be mounted on the main incomer bus bar/cable of L1, L2 and L3 phases with the correct direction of the CT (check the current flow direction marked (P1 and P2) on the respective CT, P1 is the current entry) as shown in the schematic.

This is critical to effectively operate the iSAVER

Legend: A. Power source cable and power flow B. Mounting orientation indicator arrow C. CT cables to iSaver CT connection


• It is critical that the External CT’s are positioned so that the total current (typically just after the main incomer breaker) is measured (see connection schematic on page 8).

• The CT terminals (usually marked S1 & S2 and the direction of CT current flow is marked P1 & P2) must be connected to the CT terminal block in the iSAVER unit in exactly the same sequence. Check the schematic for further clarity. (Example: The R phase CT to be connected to the R phase in the terminal block at the S1 & S2 connection point).

External CT Connection to iSAVER Models

• Similarly, connect the incoming supply main cables in the right sequence. Use only an approved cable with suitable sizing for connecting from the main distribution to the iSAVER MCCB as shown in the connection schematic.

• Connect Ground for iSAVER with an approved cable of a suitable size.

• Color coding as per required electrical standards and codes is to be followed.

• It is extremely important to ensure that the external CT primary value is entered into the controller program through HMI prior to startup to obtain the correct results and normal iSAVER operation.

Off-line Connection Verification• Conduct a continuity test of each and every connection using a multi-meter to ensure that all the sequences

are correct as per the connection schematic (on page 8) and above procedure.

• If any of the sequence is found to be incorrect, iSAVER will not work properly. It is mandatory to correct the connections.


4.Start upStart-up Procedure

The iSAVER has an advanced HMI display on the front iSaver panel providing the following displayed pages on the home screen.

These icons provide the following functions:

Live Dashboard:

Touch this icon to view the live dashboard which displays mains and load parameters.


Online screens:

Six different pages can be displayed by touching the next screen icon .

Mains Power:

Touch the arrow icon for the next screen to appear.

Touch this icon for the previous screen to appear.

Mains VAF Parameters:



Touch the online button to display the instant parameters.


Mains Energy:



Mains Power Quality:



Demand Parameters: Touch the arrow icon for the next screen to appear.



Load Parameters:



iSaver Parameters:

Touch this icon for the previous screen to appear. To view the Savings, Alarm and Live Dashboard screens, touch the icon.

and the screen below will appear.


Savings Parameter:

Touch this icon and the Savings Parameter screen will appear.

To return to the HOME screen, touch this icon

Alarm Parameters:

Touch this icon and the Savings Parameter screen will appear.

To return to the HOME screen, touch this icon


Configuration Screen:To return to the HOME screen, touch this icon . Touch this icon to view the

Configuration screen.

Password for 165KVAR machine: 165

Password for 247.5KVAR machine: 250

Touch the PASSWORD field and a numeric table will appear.


After entering the password select the ‘Enter’ button.

A Configuration screen as shown below will appear.

To change the numeric values, touch the existing field value and a numeric table will appear. Enter the new value and press the blue ‘Enter’ button. The new value will be stored in system memory.

Touch the arrow icon for the next ‘Configuration’ screen to appear.

To return to the HOME screen, touch this icon .

Touch any of the numeric fields to change the values.


To change the numeric values, touch the existing field value and a numeric table will appear. Enter the new value and press the blue ‘Enter’ button. The new value will be stored in system memory.



To return to the HOME screen, touch this icon .

To change either the Calendar or Clock values, you need to change each of the numeric fields independently, i.e DD, MM, YY

To view the OPERATIONAL SEQUENCES, select this field.

To change the OPERATIONAL SEQUENCE values, touch this field and enter a value from the numeric table that appear on the screen.


To reset the stored ‘ENERGY’ values, touch the green ENERGY PRESET button and the following screen will appear.

If you wish to clear the cumulative energy value, press the green ‘YES’ button and the existing energy value will be cleared. Click the ‘LOGOUT’ to display the live dashboard. This will display the machine performance.

Auto/manual Operation:Select the blue HOME icon , then touch the AUTO/MANUAL icon in the top right corner of the screen. The Auto/Manual screen will then appear.

Select the blue HOME icon , then touch the AUTO/MANUAL icon in the top right corner of the screen. The Auto/Manual screen will then appear.


When the machine is in ‘AUTO’ mode, this screen will appear.

Manual Mode:

In this mode, you can check each bank. If you want to turn on the first bank, click the BANK 1 ‘ON’ button. The iSaver Current and iSaver KVAR values are also displayed below each bank. To turn off the bank, click the OFF button. The Current and KVAR values will display a zero value, indicating that the bank is in OFF mode.

• Conduct a final visual check to ensure that it is safe to start commissioning the iSAVER (all connections secured, tools removed, and safety checks completed).

• Turn on the breakers within the iSAVER unit.

• Close the iSAVER main access panel door and secure the panel locks with the key provided.

• Turn ON the main incomer MCCB located on the exterior front panel door of the iSAVER. It is recommended that during this startup phase, some plant equipment is turned on to create some electrical load. It is mandatory to have a minimum of 15% KVAR load (based on the size of equipment used) to achieve an accurate startup result.

• The IP Motherboard will turn ON. This can be viewed on the HMI Live Dashboard.


Program Mode SettingsThe following information’s need to be checked and where required, data inserted in the program mode during the install process. iSAVER program settings are done as per following information:

Parameters iSaver 165 iSaver 247.5 RemarksPassword 165 250 Default setting

Panel Capacity 165 250

Voltage Rating 600 600 Setting done by factory

Pre-current Grid/Mains The Mains CT rating should always be higher than the iSAVER CT. Mains CT(s) should be located on the main incoming phases to measure complete load for maximum benefit.

Pre-current iSaver 250 400 Default setting

MD Current Maximum Demand Current value of the factory to be set

PF Set-Mains 1 1 Setting done by factor

PF Set-DG 0.9 0.9 Setting done by factor

Connection Delay 3 sec 3 sec Setting done by factor

Re-ConnectionDelay

5 sec 5 sec Setting done by factor

First Bank Rating 27.5 27.5 This is the smallest bank and is activated only when the load reactive power is >70% of its value (>8.75)

Number of Banks 3 4 These are the number of modular banks (default value).

Modem ID Setting done by factory

Calendar DD:MM:YYYY. This isan important setting to input and have correct web-based data.

Clock HH:MM:SS. This is an important setting to havecorrect web-based data.

Operational Sequence 3 - (1:2:3:3:3) 3 -(1:2:3:3:3) Setting done by factory

Over Temp 131 131 Setting done by factory


You can verify the iSAVER functionality in following manner:

Press the ONLINE button on the HMI screen. There are three different screens. Enter the parameter value, select the LOAD parameters screen and obtain the information that appears below for iSAVER(OFF). Select the MAINS parameter page and the information for iSAVER(ON) with appear.

Parameters iSAVER OFF iSAVER ONA (L1) B (L2) C (L3) A (L1) B (L2) C (L3)

Voltage (L-L)CurrentPFKWKVAKVAR

After obtaining the cell values that appear in each of the iSAVER (ON) columns, the effective operation of your iSAVER unit can be determined.

Voltage verification

Use a phase confirmation device to check that the phases are correct. If the orientation of these is known, it will be easier to alter the phase connection to the unit.

Verify that all the Phase connections are correct. An easy way to verify is to measure the voltage on each of the phases, to confirm if the connections are correct. For example, if the R phase measures 347V (P-N) at the mains, it will be verified if it measures almost the same 347V at the iSAVER R connection.

* Worksheet left intentionally blank. This worksheet is for the installer to complete


Check Mains CT polarity on the bus bar

Current flow

After installing the MAINS CT and voltage connections, undertake a visual check using the steps below:

• Check the Mains CT secondary wires (S1, S2) to ensure the correct polarity as shown in the schematic. This implies, that the R phase CT should be connected to the R phase bus bar.

• Check Y and B phase CT location as well as their respective CT secondary wires to properly connect as per the above schematic diagram.

iSAVER parameters check

After completing the iSAVER installation, based on the instruction input parameters into the IP Motherboard (as per the provided data sheet), re-check the PT and CT polarities. The load on the iSAVER at this time should be at least 15%.

To verify the PT and CT connection on the IP Motherboard, proceed to the display page and check/ Records on the commissioning data sheet the following parameters on the HMI screen.


• Total KW

• Total KVA

• Total KVAR

• Mains PF

• Individual KW (A, B, C)

• Individual KVA (A, B, C)

• Individual KVAR (A, B, C)

• Individual PF (A, B, C)

Data Communicator Observation

The display on the Data communicator should have the following lights once connected and SIM card inserted:

• Amber Power light on

• Green Signal light on

• The Red light adjacent to the Amber light will begin to search for server and will turn on-off at a regular pace @1:1. This may take up to 2 minutes, and when the signal is locked in securely, this light will turn on-off at a much higher pace @ 1:2.

• As soon as the above occurs, the green light next to this RED light will light up.

• The RXT/TXT lights on the Data communicator will turn on-off at regular intervals.


5.Periodic MaintenancePeriodic Off-Line Maintenance Recommendation

Depending on the operating environment, a six-monthly internal inspection by an authorized person is highly recommended. During this inspection, if any dust has accumulated, it can be vacuumed/removed, and air filters cleaned and/or replaced. At the same time, verify the integrity of the cable connections to ensure that they are tightly fastened.

Periodic On-Line Diagnostic Test

This is recommended to be done once in six months by the client or maintenance staff. The unit will continue to operate normally automatically while the diagnostic test is conducted.

When you turn on 27.5 KVAR, 55 KVAR or 82.5 KVAR, the current flowing will be nearly same as the values that have been mentioned in the DEFAULT CURRENT table below.

Default Current value details for Capacitor Bank

iSAVER- IPMBank ON Indication

iSAVER 165 iSAVER 247.5KVAR AMPS KVAR AMPS

C1 27.5 26.5 27.5 26.5

C2 55 53 55 53

C3 82.5 79 82.5 79

C4 82.5 79

There could be slight variation of (+/- 10%) due to incoming voltage variation. This diagnostic test confirms that all the functionality of the ISAVER is normal.

If there is any abnormality in the above, an Off-Line check will be required to check that the corresponding stage switching Module, Thyristor and Capacitor.

Refer to the Troubleshooting Guide below, and if required, contact your equipment distributor.


6.Troubleshooting

Ref. No.

Fault Causes Rectification

1 No display on iSAVER, HMI screen.

24V DC SMPS power output failure.

Potentially no aux. supply voltage. Check to see if the Control MCB (2 pole) has tripped.

Check the SMPS output voltage 24VDC.

If it is not working replace the SMPS.If MCB has not tripped, check the volt-age (230VAC) in the secondary portion of the MCCB Bus bar.

2If Thermal controller and Data communicator are not ON.

230 VAC AUX supply may have failed. Check the SMPS input voltage (230V) and the output voltage (24VDC) to ensure that the SMPS is functioning normally. If the output voltage is incorrect, the SMPS is faulty. Replace SMPS.

In case the SMPS input does not have voltage, check the control MCB and corresponding path.

3 Cooling fan(s) not op-erating

Any one fan not running

Door fans not operating or not running.

Cooling fan may be faulty.

This is normal as the fans will Oper-ate only when the set temperature of the thermal controller exceeds the set point.

Check the voltage supply (230VAC) across the fan terminal. If voltage the voltage supply is correct, it is likely that the fan has developed a fault. Replace the fan with a similar fan.

When the temperature reaches the set point, the fans will start automatically.

In case the fans do not operate, despite the chamber temperature higher than set point, the unit will safely trip the capacitor banks. The unit will need off-line investigation to check the integrity of the thermal controller.


Ref. No.


4 IP Motherboard does not switch on the capacitor banks and the alarm indication glows.

Over voltage alarm

Over current alarm

Zero voltage alarm

Zero current alarm

Over temperature (Front chamber / Rear chamber) alarm.

Incoming voltage may be constantly high. (More then 10%). When voltage becomes normal, the iSAVER will start functioning.

Mains current is more than 120 % of CT primary.

When current returns to normal, the iSAVER will start functioning normally.

Voltage PT input for the iSAVER may be failed.

NO load or the CT connection is open.

iSAVER temperature (Front chamber or Rear chamber) is high.

Check cooling fans and fan thermostat are functioning.

5 IP Motherboard mains current / iSaver current reading incorrect.

Potentially wrong CT settings on Controller.

CT faulty or potentially failed.

Check - controller Primary Current program settings and correct.(i.e. if 400/5A CT’s are used, insert CT value in controller as 400A).

Check the CT output current corresponding to primary. It should be close to 5 Amps.

If output current is not correct as per CT value, the CT is defective and should be replaced.

6 IP Motherboard indicates negative mains KW reading.

CT polarity reverse connection / Incorrect CT wiring.

Conduct a continuity check to ensure that the CT connections are as per installation procedure above.

7 Power Factor is low with the following conditions:• NO Alarm• NO banks are ON.

Very low reactive load. Connected load lower than 70% value of first Capacitor bank.

Check the first capacitor bank value in program mode.

In our current design, the Capacitor correction steps are auto activated when measured KVAR is more than 70% of the minimum step. No correction action is required.

Check all three CT outputs. If there is an incorrect value showing, correct/change the corresponding CT.


Ref. No.


8 Capacitor banks are ON, but no PF improvement/ change shown by controller. (External mains CT type).

Mains CT may be incorrectly Installed. Check and verify installation procedure.

Mains CT should be placed on the mains side. Check and verify installation procedure. Refer to the connection diagram.

9 IP Motherboard showing erratic reading of kW, KVAR & PF.

This is caused by CT phase reversal or polarity reversal.

Check the CT connection and correct it as per connection diagram and procedure.

Always ensure the corresponding phase of CT is connected to corresponding terminals with the correct polarity.

10 Surge arrester integrity periodic checking.

- Green - Normal Red - Failure Red - FailureRed indication means the surge arrestor element is protecting the equipment from a large surge event.

Remove the failed surge module displaying the red indicator and replace it with a new surge module (will have green indicator).

Advanced Troubleshooting11 The LED light on SMPS

(which indicates output) is not glowing.

Input supply may have failed.

SMPS failure.

Check if the SMPS MCB has tripped. Reset the MCB

MCB has not tripped but the Green LED light is not glowing, the SMPS has potentially become defective. Replace SMPS module.

12 The unit is ON but the Power Factor has not improved.

Also, in this condition, if there is;• No Alarm in

controller.• No bank has

switched ON.

The controller settings may be incorrect. If the controller settings are not set to unity (default value), this issue may arise).

Check all the settings through the procedures provided in the controller section of this manual and reset the values. Once the values are corrected, the unit will activate to normal operation indicating improved Power Factor.


Ref. No.


13 The unit is ON but the Power Factor has not improved.

Also, in this condition if there is:• Under

compensation Alarm is ON

• All banks are ON indication glow.

Any Individual Step MCB/MCCB may be tripped.

Potential malfunction of Dynamic Switching Module (EDS).

Capacitor capacity reduction/failure.

Check if the MCB are off / tripped.

If the MCB is off or tripped, check carefully to observe any abnormality through a visual inspection. If nothing is observed, reset the MCB

Check the indication in Dynamic Switching Module as follows:

1. No indication found. (With panel ON, the Ready LED indicator should glow). If this does not happen, verify the voltage of the auxiliary supply, and ensure it is 24VDC.

2. If auxiliary supply is not detected or of correct value, check the SMPS.

3. If aux. supply is correct, the EDS may need off-line inspection/ repair and should be replaced with a new EDS module.

4. In case the Ready LED indication is glowing, but the remaining indications are not glowing.

5. Check for trigger voltage (12v- 24VDC).

6. If this is not detected, check the Heat sink thermostat / Harmonic Reactor thermostat whether they are open (as a safety measure, high temperature opens these thermostats). When the temperature is lowered to the set point, your ISAVER will again function normally. Standard internal temperature is 50°C.

7. If the thermostats are found defective, replace the thermostat(s).


Ref. No.


13 1. In case the Ready and Trigger LED indication are glowing, yet the EDS module indicates a trip indication there is a Potential Thyristor malfunction/failure and needs off-line repair.

2. Check if the capacitors are taking the rated current. This can be done through the diagnostic

3. If the thermal controllers are found defective, replace thermostat(s).

4. If the Ready and Trigger LED indicators are glowing but the EDS module indicates a trip indication, there is a Potential Thyristor malfunction/failure and needs off- line repair.

5. Check if the capacitors are taking the rated current. This can be done through the settings of the controller and described in this manual.

14 During diagnostics if any capacitor bank is found to have less than80% current per KVAR than its rated current per KVAR at the specified voltage, then the capacitors need changing.

Capacitor may have been de-rated in value.

Replace the capacitor.

15 If a capacitor bank consumes high current despite being switched off.

Thyristor may be faulty (short). Check and replace the thyristor.

16 If the bank indicator on the controller is on, yet the trigger LED on the EDS switch does not flicker/glow.

Possible fault with the thermostats on the heat sink/harmonic reactors.

It will auto reset after temperature is reduced.

Check thermostats as they should be normally closed (NC). In case they are open (NO) replace the thermostats.


Ref. No.


17 LED light on EDS module does not glow.

No 24V DC supply may be available or EDS module failure.

Check the SMPS output for 24V DC and SMPS output LED indication.

If 24V DC output is found, check 220V AC input to SMPS.

If 220V AC input is fine, it is possible that the SMPS has failed. Replace SMPS.

If there is no 220V AC input, check if the control MCB control has tripped.

Check for 12V DC aux. supply in EDS aux input terminal.

18 No LED indication on the EDS trigger despite the bank being turned on.

Heat sink thermostat/harmonic filter thermostat faulty.

Switch off the panel, check the corresponding thermostat for NC using a multi-meter. If thermostats are open, it may be due to over temperature or fault condition. After a few minutes recheck the thermostat.

If thermostat shows open, replace the thermostat.

19 EDS Module ‘Trip indication’ shown.

Respective MCCB may be switch OFF.

NO voltage feed to the thyristor module.

Thyristor failure.

Check the MCCB and voltage feed to the Thyristor module.

Check the Thyristor. If this has failed, replace the unit.

20 All Capacitor banks turn ON without any required KVAR load

Mains CT location at wrong place. Check the Mains CT coil location. It should be placed before the iSAVER panel voltage cable. This allows the Saver current to also flow through the Mains CT.

If it is incorrectly located, please change the CT location to be before the iSaver voltage cable.


7.Limited WarrantyEncorp Canada warrants to the original purchaser that

products sold shall be free from defects in material and

workmanship for the warranty period of three years from

the Date of Purchase.

If buyer claims that a product violates this Limited

Warranty, Encorp Canada, upon notice promptly given,

will either examine the product at buyer’s site, or issue

shipping instructions for return to Encorp Canada at

buyer’s expense, transportation charges prepaid.

Encorp Canada’s sole obligation under this Limited

Warranty shall be, at its option, to repair, replace or

refund the price of any product thereof which is proved to

violate this Limited Warranty.

In no event, whether based on contract, indemnity,

warranty, tort (including negligence), and strict liability or

otherwise, shall Encorp Canada be liable to the buyer for

special, indirect, incidental, or consequential damages

whatsoever including, without limitation, loss of profit or

revenue.

THIS LIMITED WARRANTY IS THE BUYER’S EXCLUSIVE

REMEDY AND ENCORP CANADA HEREBY EXPRESSLY

DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR

IMPLIED, INCLUDING THE IMPLIED WARRANTY OF

MERCHANTABILITY AND THE IMPLIED WARRANTY OF

FITNESS FOR A PARTICULAR PURPOSE.

The foregoing shall constitute the sole remedy of the

buyer and the sole liability of Encorp Canada.

This Limited Warranty shall not apply to any product

or component thereof which has been repaired or

altered by anyone other than Encorp Canada authorized

personnel in any manner so as, in Encorp Canada’s

sole judgment, to affect its serviceability, or to any

product that has been subject to alteration, accident,

misuse, abuse, neglect or normal wear.

This Limited Warranty shall not apply to products which

have been assembled or installed or used in a manner

contrary to Encorp Canada’s printed instructions, or due

to failure to follow Encorp Canada printed instructions

for operation and maintenance.

Any technical assistance provided by Encorp Canada’s

personnel or representatives in system design is

construed to be a proposal and not a recommendation.

The responsibility for determining feasibility rests with

the user and should be subject to test.

Only the terms expressed in this Limited Warranty

shall apply and no distributor, corporation or individual

is authorized to amend, modify or extend this Limited

Warranty in any way on resale.

For product return authorization, speak to your local

distributor or contact Encorp Canada.

[email protected]

www.encorpcanada.com

Encorp Canadatel: 519 300 6010 [email protected] www.encorpcanada.com

Date post:	27-Oct-2021
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iSAVER DPFC 165 & 250 Series ‘The Eliminator’

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