OPERATING MANUAL iSAVER DPFC 450 & 650
‘The Eliminator’
Encorp Limited, 666 Great South Road, Level 3, Building 10, PO Box 17 506 Greenlane, Auckland 1546, New Zealand
tel: +649-928-7901 mobile. +6421-074-6273 email: [email protected] www.encorp.co.nz
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TABLE OF CONTENTS
Section 1 Introduction 3
Section 2 Specifications 6
Section 3 Installation 9
Section 4 Start-up 12
Section 5 Periodic Maintenance 20
Section 6 Troubleshooting 22
180419: DPFC 450-650 manual v5
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1Introduction
iSaver Manual
This 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 Precautions
The 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 lightings, 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.
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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 switchgear, voltage fluctuations due to high kVA draw, lowers heating of switchgear, transformers and local network. iSaver technology also compliments environmental sustainability by improving higher efficiency.
* subject to customer tariff structure
Features
• The iSaver uses a fully automatic Encorp Dynamic Controller (Microcontroller 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 real time, 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 switchgear 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 over load protection provided through MCB or MCCB.
• Over temperature protection is provided by shutting downing the Encorp Dynamic Switching manual (EDS) to provide complete safety.
• iSaver cooling and ventilation system is operated automatically only when required minimizing the units power consumption and power foot print.
• The modular design can be adapted for custom applications 150kVAr to 650kVAr
• High Voltage Surge protection provided (as option).
• Remote web based on-line performance monitoring option also available.
Benefits
• Total Power Bill* is reduced based on the site operating conditions
• Demand Charge and Power Factor related charges (Penalty, additional charges imposed by utility for low efficiency etc.) are significantly reduced.
• Wastage and switchgear 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 foot print is reduced contributing to improved environmental sustainability.
• Reduces total connected total power (kVA) requirement from utility. This results in cost avoidance for upgrades and availability of additional power is almost instantaneous.
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• The web based performance monitoring feature of iSaver enables online viewing and is very useful to monitor the end users load and any abnormal/faulty conditions remotely.
Application
Industries 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 Equipment
iSaver 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.
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2Specifications
Standard Specification for iSaver 450 DPFC
Model iSaver 450Voltage Input 600 VAC 60HzSupply Three PhaseConfiguration 3 Phase – 4 WireRating 450 kVArCurrent Rating 450ABanks 1x50 +(4x100) kVArSequence 1:2:2:2:2Logic The unit is designed to operate in steps of 50 kVArMinimum Step 70% of the lowest Bank Capacity (35 kVAr)Control Operation Controlled real time switching output based on load requirements.Controller Microcontroller based advanced electronic controllerTarget Efficiency > 98% (+/- 3%) for Canadian Voltage and frequencyiSaver Display 3 row crystal clear backlit LCD display of RMS valuesWeb Monitoring On Line iSaver parameters display (PF, kVA, kVAh, kW, kWh, kVAr,
kVArh, Hz, V-THD, I-THD, Status, Alarms, Time Integrated data.Diagnostic feature iSaver internal key component functional analysis and status displayiSaver Monitor Displays main and ISaver (panel) parameters locally and remotelyDG operation Dedicated PF setting for DG operationDisplayed Data PF, kVA, kVAh, kW, kWh, kVAr, kVArh, Hz, V-THD, I-THDMain Protection Short circuit and Over- load protection (MCCB 600A/50KA-3Pole)Bank Protection Short circuit and Over- load protection (MCCB & MCB) and Thermal
safety trip(s). Unit automatically resumes operation once fault is corrected.
Protection Thermostats operated over temperature protection of enclosure cham-bers (Both Front and Capacitor Chamber), Harmonic Reactors and Capacitors.
Construction Robust Standalone metal enclosure (indoor application only)Dimensions 2000 (H) x 1100 (W) x 750 (D) mmWeight 620Kg [± 3 %]Mounting Floor Mounting with Foundation BoltsEnclosure Powder coated corrosion resistant sheet steel enclosure (RAL 7035)Transient protection ProvidedCable Entry Bottom and side entry provision.
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Standard Specification for iSaver 650 DPFC
Model iSaver 650Voltage Input 600 VAC 60HzSupply Three PhaseConfiguration 3 Phase – 4 WireRating 650 kVArCurrent Rating 650ABanks 1x50 + (6x100) kVArSequence 1:2:2:2:2Logic The unit is designed to operate in steps of 50 kVArMinimum Step 70% of the lowest Bank Capacity (35 kVAr)Control Operation Controlled real time switching output based on load requirements.Controller Microcontroller based advanced electronic controllerTarget Efficiency > 98% (+/- 3%) for Canadian Voltage and frequencyiSaver Display 3 row crystal clear backlit LCD display of RMS valuesWeb Monitoring On Line iSaver parameters display (PF, kVA, kVAh, kW, kWh, kVAr,
kVArh, Hz, V-THD, I-THD, Status, Alarms, Time Integrated data.Diagnostic feature iSaver internal key component functional analysis and status displayiSaver Monitor Displays main and ISaver (panel) parameters locally and remotelyDG operation Dedicated PF setting for DG operationDisplayed Data PF, kVA, kVAh, kW, kWh, kVAr, kVArh, Hz, V-THD, I-THDMain Protection Short circuit and Over- load protection (MCCB 1000A/50KA-3Pole)Bank Protection Short circuit and Over-load protection (MCCB & MCB) and Thermal
safety trip(s). Unit automatically resumes operation once fault is corrected.
Protection Thermostats operated over temperature protection of enclosure cham-bers (Both Front and Capacitor Chamber), Harmonic Reactors and Capacitors.
Construction Robust Standalone metal enclosure (indoor application only)Dimensions 1600 (H) x 1600 (W) x 800 (D) mmWeight 750Kg [± 3 %]Mounting Floor Mounting with Foundation BoltsEnclosure Powder coated corrosion resistant sheet steel enclosure (RAL 7035)Transient protection ProvidedCable Entry Top entry provision.
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Connection Schematic for iSaver 450
Connection Schematic for iSaver 650
Suggested minimum connection cable size
iSaver Rating Rating of Main incoming breaker
Suggested minimum cable rating (3/3.5 core)
Suggested cable rating (ground & neutral)*
iSaver 450 600A 2 set of 400 Kcmil) Per regulatory requirements
iSaver 650 1000A 2 set of 800 Kcmil) Per regulatory requirements
* Based on maximum current rating of the iSaver incoming breakers
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3Installation
Step by Step Connection
• This equipment must only be installed and serviced by qualified electrical personnel.
• Place the iSaver DPFC 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 top 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-DPFC should be routed through the rubber gourmet and the gland reinstalled.
• Turn down the Power to the distribution board and ensure it is de-energized and safe to connect.
• Ensure the main breaker of distribution board and iSaver breakers are in ‘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 600A, the CT to be used should also be rated as 600/5 Amps, 600V AC). Sometimes, the physical installation clearance and bus bar size etc. will determine the internal diameter of the CT coil to be used.
The CT’s have to 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.
It is critical that the External CT’s are positioned wherein the total current (typically just after the main incomer breaker) to enable the measurement of the total current flowing through the main breaker (see schematic)
The CT terminals (usually marked S1 & S2 and the direction of CT current flow is marked P1 & P2) should 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).
Legend: A. Power source cable and power flow B. Mounting orientation indicator arrow C. CT cables to iSaver CT connection
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External CT Connection to iSaver DPFC
Similarly connect incoming supply main cables in the right sequence. Use approved cable with suitable sizing for connect from the main distribution to the iSaver MCCB as shown in the connection schematic.
iSaver Rating Rating of Main incoming breaker
Suggested minimum cable rating (3/3.5 core)
Suggested cable rating (ground & neutral)*
iSaver 450 600A 2 set of 400 Kcmil) Per regulatory requirements
iSaver 650 1000A 2 set of 500 Kcmil) Per regulatory requirements
* Based on maximum current rating of the iSaver incoming breakers
Connect Ground for iSaver-DPFC with approved cable with suitable sized
Color coding as per required standards and codes is to be followed.
It is extremely important to ensure that the external CT primary value is inserted in the controller to obtain correct results and normal iSaver operation.
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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 and above procedure.
If any of the sequence is found to be incorrect, iSaver DPFC will not work properly. It is mandatory to correct the connections.
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4Start up
Start-up Procedure
Conduct a final visual check to ensure that it is safe to start commissioning the iSaver (all connections secured, tools removed, safety checks completed)
Turn on all breakers within the iSaver unit.
Close the iSaver main access panel door and secure the panel locks.
Turn ON the main incomer MCCB to the iSaver. It is recommended that during this start up 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 have accurate startup results.
The iSaver controller will turn ON indicating Mains parameters.
iSaver Dynamic Controller
Setting the controller
By pressing ���� and
��� keys simultaneously for a few seconds, the program mode is selected. The display
shows the following screen;
EDC 814iSaver Dynamic Controller
MODE MORE
AUTOMAN AL.ACK
A/M C1 C2 C3 C4 C5 C6 C7 C8 ALR
RXD
TXD
ENERGY TECHNOLOGIESncorpC
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PROG PASSWORD
/ / / /
In case it is desired to set a new password, press ���� key and the first slash (digit) will start blinking. (Please note
the factory default is 0000).
Now, select ��� key and each time it is pressed, the digits will change. Insert the default password and press
AL.ACK�key and the following program mode screen will appear.
PROGRAM MODE
Press MODE
key and the following screen will appear
METERING SETUPNEW PASSWORD
0000
To change to a new password
By using ���� and
��� keys, enter the new password and then press
AL.ACK�key. The new password is
now set- record this securely as all future access to the controller will require this authorization password.
To change to Operating Voltage
By using � keys, the following screen will appear.
METERING SETUP
OPERATING VOLTAGE
0600
If the operating voltage is to be changed, press ���� key and the first slash (digit) will start blinking. Now, select
��� key and each time this is pressed, the digits will change. Insert the currosponding operating voltage and press
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AL.ACK�key the new operating voltage is now set. The new operating voltage is now set.
To set Mains CT primary current
Press � key to select select Mains CT primary Current value. (Ex. If a 1000/5A CT is used, then the primary value should be set to 1000 in the four digit format as follows)
METERING SETUPMAINS PRIMARY CURRENT SET
1000
It is essential to set the Mains CT primary current value. To do this, press ���� key and the first slash (digit) will
start blinking. Now, select ��� key and when this is pressed, the digits will change. Insert the currosponding CT
primary value and press AL.ACK�
key to save setting. The new mains primary current is now set.
To set iSaver CT primary current
Press � key to select select iSaver CT primary Current value. (Ex. If a 400/5A CT is used, then the primary value should be set to 400 in the four digit format as follows)
METERING SETUP
iSaver PRIMARY CURRENT SET
0600
It is essential to set the iSaver CT primary current value. To do this, press ���� key and the first slash (digit) will
start blinking. Now, select ��� key and when this is pressed, the digits will change. Insert the currosponding CT
primary value and press AL.ACK�
key to save. The new iSaver primary current value is now set.
To set the Clock
By using �
keys, the following screen will appear.
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METERING SETUP
CLOCK12:10:54
It is essential to set (RTC) clock to the correct local time. To do this, press ���� key and the first slash (digit) will
start blinking. Now, select ��� key and when this is pressed, the digits will change. Change to the correct time and
press AL.ACK�
key the new Time is now set.
To set the Calendar
By using � keys, the following screen will appear.
METERING SETUP
Calendar20:04:2016
It is essential to set Calendar to the local date settings. To do so, press ���� key and the first slash (digit) will start
blinking. Now, select ��� key to change the digits to the correct date. Insert the present Date/Month/Year and
press AL.ACK�
key the-new Date/Month/Year is now set.
To set Device ID
By using �
keys, the following screen will appear.
METERING SETUP
Device ID001
In order to get on-line monitoring active, it is essential to set the device ID. Press ���� key and the first slash (digit)
will start blinking. Now, select ��� key and when this is pressed, the digits will change.
To set the Modem Device ID, as detailed on the back panel of the modem, insert the corresponding device ID and
press AL.ACK�
key. The new device ID is now set.
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To set display to Screen Power save mode
By using �
keys, the following screen will appear.
METERING SETUPLCD POWER SAVE
Disable
If it is desired that the LCD back light is always turned On, select the disable mode by pressing ���� key and
pressAL.ACK�
key to save.
If it is desired to have the back light constantly On, select Enable by press ��� key and press
AL.ACK�key. This
will set the LCD back light to be set in ON mode.
To set Energy Reset and Clear
By using � keys, the following screen will appear.
METERING SETUP
Energy Reset?
If the meter needs to be reset, press AL.ACK�
enter key, the following screen will appear.
METERING SETUPENERGY RESET
DONEENTERED
and the previous energy and average PF are reset to Zero.
Note: By doing this, we can see AVG. PF maintained by the panel from the installation.
All other remaining setting are done in the Factory based on the panel rating. Factory setting details in end of startup procedure.
After completing the setting. Return back from the program mode by pressing ���� and
��� keys
simultaneously.
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By using the selection key � select the main PT seq and CT rev display page. (Refer iSaver controller operating Manual for detailed operation).
iSaver Basic Diagnostic Features:
iSaver controller has the diagnostic features for PT sequence and CT Reversal indication. The following screen indicates the correct sequence of connection.
MAINS PT SEQ : ABC CT REV : NIL
This screen check post-installation of CT and prior to start up will ensure voltage supply connected is in the correct ABC Sequence and CT is connected in the correct polarity.
If there is any incorrect PT sequence, the display will show the following screen:
MAINS PT SEQ : ACB CT REV : NIL
Recheck the CT connections and installation and correct prior to start-up
In case the CT direction is incorrect and there is any CT polarity reversal, the display will show the following screen;
MAINS PT SEQ : ABC CT REV : B
This indicates that the B phase (L2) phase CT polarity is reversed. To correct inter change the S1 and S2. Recheck to ensure it is correct prior to start-up.
Manual Parameters Display Selection
By using the �
and MORE
key select various mains parameter like voltage, current, PF , KVA, KW & KVAR, PF, THD etc.
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You can verify the ISaver functionality in following manner
Press the AUTOMAN key, the LED on the controller panel marked A/M will glow indicating that the unit is now on
Manual Mode.
By pressing���� key, gradually switch OFF all capacitor banks. After about one minute of switching off all banks,
note the mains reading in the respective iSaver (OFF) columns.
ParametersiSaver (OFF) iSaver (ON)
A(L1) B(L2) C(L3) A(L1) B(L2) C(L3)Voltage (L-L)Current PFKWKVAKVAR
Once all the readings are noted, Press AUTOMAN
key and change the controller from manual mode to auto mode. This will be confirmed by the Manual LED light turning off and capacitor banks (C1, C2, C3 etc.) automatically starting to turn on as required by the load demand.
After few minutes of stabilization when the panel readings stabilize, note the readings in iSaver (ON) columns. Using this information, the effectiveness of the iSaver can be computed.
To verify the iSaver capacitor bank current on line using the controller, the iSaver current page display can be checked through the following sequence;
Pressing MODE
key, select iSaver parameter display page. The Display will show the following page;
iSAVERCURRENT
A 50.0 B 50.0C 50.0 ∑ 50.0
Now unit will operate automatically and the display panel will indicate all important parameters in a scrolling mode.
Metering Default Setup
Setting parameters iSaver 450 DPFC
iSaver 650DPFC
New password 0000 0000Operating voltage 600 600
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Mains CT primary NOTE 1 NOTE 1ISaver CT primary 600 1000Clock NOTE 2 NOTE 2Calendar NOTE 3 NOTE 3Device ID NOTE 4 NOTE 4LCD power saver DISABLED DISABLEDEnergy reset sure NOTE 5 NOTE 5
NOTE 1: External mains CT primary value to be set.
NOTE 2: Local Time to be set
NOTE 3: Local Date to be set
NOTE 4: Corresponding communication ID to be set .if used, otherwise on setting required.
NOTE 5: To reset the energy and avg.PF when ever require. (It recommended during installation).
Default Control setup
Setting parameters iSaver 450 iSaver 650EB PF Set point 1.00 1.00DG PF Set point 0.80 0.80Connection delay 02.0 02.0Reconnection delay 005 005NO. of Banks 5 71st bank value 50 50Operating sequence 1:2:2:2:2 1:2:2:2:2
Default Alarm setup
Setting parameters iSaver 450 iSaver 650Over voltage set(%) 110 110Over current set (%) 120 120Current THD (%) 30 30
Fan Temp Setup
Thermostat Location
iSaver 450Temp Range
in degree Celsius
iSaver 650Temp Range
in degree Celsius
Front Door Fan 30 30Back Door Fan 30 30Front Temp Trip 50-55 50-55Back Temp Trip 50-55 50-55
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5.Periodic Maintenance
Periodic Off-Line Maintenance Recommendation
Depending on the operating environment, a six-monthly internal inspection is highly recommended. During this inspection, if any dust has accumulated, it can be vacuumed/removed. Verify integrity of connections to ensure tightness.
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.
Press selection key MODE
and � select the iSaver current display page.
iSAVER CURRENT A 50.0 B 50.0 C 50.0 ∑ 50.0
Now press the key AUTOMAN Auto/Man.
The LED marked A/M will glow indicating that the unit is now on Manual Mode.
Press ���� and the Capacitor will be switched OFF. Continue this till all the capacitors are switched OFF.
Press ��� key and the Capacitor bank will turn ON.
Check the corresponding change in capacitor bank current in iSaver current display page.
Verify the current value corresponding to the Bank ON indication (C1,C2,C3,C4,C5,C6,C7)
Press ���� and the Capacitors will switch OFF.
The above step is to be repeated for all the Banks and values verified as per the following default Current values table below.
Once completed, return back to the normal mode by pressing AUTOMAN key.
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Default Current value details for Capacitor Bank
iSaverBank ON Indication
iSaver 450 iSaver 650KVAR AMPS KVAR AMPS
C1 50 48 50 48C2 100 96 100 96C3 100 96 100 96C4 100 96 100 96C5 100 96 100 96C6 - - 100 96C7 - - 100 96
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.
In case there is any abnormality in the above, a Off-Line check will be required to check the corresponding stage switching Module, Thyristor and Capacitor. Refer to troubleshooting guide and if required contact your equipment distributor.
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6.Troubleshooting
Ref. No.
Fault Causes Rectification
1 No display on iSaver controller.
24V and 12V SMPS power output fail.
Cooing fan not running.
Potentially no aux. supply voltage. Check to see if the Control MCB (2 pole) has tripped.
If MCB has not tripped, check the voltage (230VAC) in secondary of the control transformer.
Check the 600V in primary of control transformer to ensure that the second-ary voltage is 230V.
If there is no voltage in the control transformer, check the fuse link in the primary side.
In case the fuse is fine and the primary voltage is correct, then the Control transformer may have failed. Replace with a new transformer.
2No display on iSaver controller
24VDC Aux, supply may have failed Check SMPS 1 for 24VDC at output terminal and the controller Aux input. If voltage is correct, there may be a fault with the controller. Replace the controller.
Check the SMPS 1 input voltage (230V) and the output voltage (24VDC) to ensure that the SMPS is functioning normally. In case 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.
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3 Cooling Fan(s) not operating
Any one particular fan not running
Front door fans not operating or back door fans not running.
Particular cooling fan may be faulty.
This is normal as the fans will operate only when the set temperature of the thermostat exceeds the set point.
Check the voltage supply (230V) across the fan terminal. If voltage supply is correct, it is likely that the fan has developed 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 temperature is 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 thermostats.
4 iSaver controller mains voltage shows er-ratic readings or displays zero.
Voltage module output (PT input for the iSaver) voltage may have failed
Check the output voltage of voltage module corresponding to the input voltage. (20VAC to 24VAC).
If output voltage fails. Voltage module may have failed. Replace the voltage module.
If the input to the voltage module fails. Check the fuse links.
5 iSaver controller 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 (chamber 1 or chamber 2) 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 module output (PT input for the iSaver) may be failed
Check the voltage module and replace if required.
NO load or the CT connection is open.
iSaver temperature (chamber 1 or chamber 2) is high.
Check cooling fans, and fan thermostat are functioning.
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6 iSaver Controller 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 corre-sponding to primary. It should be very close to 5 Amps.
If output current is not correct as per CT value, the CT is defective and should be replaced.
7 iSaver Controller indi-cates 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
8 Power Factor is low with the following conditions:• NO Alarm• NO banks are ON
Very low reactive load. If the connected load is lower than 70% value of first Capacitor bank value, the first bank will not turn ON.
Check the 1st capacitor bank value in program mode.
In our current design, Capacitor cor-rection steps are auto activated when Measured kVAr is more than 70% of the minimum step.
No corrective action required.
Check all three CT outputs. If any CT indicates wrong value, correct / change the corresponding CT.
9 Capacitor banks are ON, but no PF improve-ment / 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 installa-tion procedure. Refer to the connec-tion diagram.
10 iSaver Controller show-ing 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 correct polarity.
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11 Surge arrester elementIntegrity periodic check-ing
Green - NormalRed - Failure Red - Failure Red indication means surge arrestor element protected the equipment from a large surge event and in the process failed.
Replace the failed surge element with the red indicator.
Advanced12 The Green LED light on
SMPS indicating 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.
13 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 incor-rect. If the controller settings are not set to unity (default value), this issue may arise)
Check the settings through the procedure 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.
14 The unit is ON but the Power Factor has not improved.
Also, in this condition, if there is:• Under compensation
Alarm is ON• All bank 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:
a) No indication found. (with panel is ON, the Ready LED indicator should glow). If this does not hap-pen, verify the voltage of the auxil-iary supply and ensure it is 12VDC.
b) If auxiliary supply is not detected or
of correct value, check the SMPS.
c) If aux. supply is correct, the EDS may need off-line inspection/ repair and should be replaced with a new EDS module.
– Page 26 –
14 The unit is ON but the Power Factor has not improved.Also, in this condition, if there is; • Under compensation
Alarm is ON• All bank are ON
indication glow
Any Individual Step MCB/MCCB may be tripped
Potential Malfunction of Dynamic Switching Module (EDS).
Capacitor capacity reduction/ failure
d) In case the Ready LED indication is glowing but the remaining indications are not glowing:
• Check for trigger voltage (12v-20V).
• If this is not detected, check the thermostat on the Heat sink / Harmonic Reactor ther-mostat as when these are open (safety against high tempera-ture opens these thermostats).
• Check the controller back side T1, T2 terminals which is used for over temperature trip it has connected through panel thermostat if it deducted the over temperature then feed-back goes to iSaver controller then automatically all capacitor banks will getting OFF one by one.
• Then temperature comes down the set point then isaver function will work normally normally panel internal temp set was 55°C.
• If the thermostats are found defective, replace thermostat(s).
In case the Ready and Trigger LED indication are glowing but yet the EDS module indicates a trip indication there is a Potential Thyristor malfunction/failure and needs off-line repair.
15 Any Particular bank taking less than rated current/ KVAr.(less than 80%) at rated voltage
Capacitor may have been de-rated in value
Replace the capacitor
16 Any particular bank consuming current / KVAr without controller command
Thyristor may be faulty (short) Check and replace the thyristor.
– Page 27 –
17 For any particular bank ISaver Controller bank on indication is present but in particular EDS trigger on indication does not glow
Heat sinks Thermostat/harmonic reactor thermostat open due to over temperature.
It will auto reset after temperature is reduced.
Check the thermostat continuity under cold condition, if faulty replace the thermostat.
18 In EDS ‘Ready’ indication not glow.
Ready Indication not glow in all EDS
Ready Indication not glow in particular EDS
12VDC aux. supply may not be available.
12VDC aux. supply may not be available (or) EDS module failure.
Check the SMPS output for 12VDC and SMPS output LED indication.
If 12VDC output not found , check 220VAC input in SMPS.
If 220VAC input OK, SMPS failure, replace the SMPS
If 220VAC input not coming, check for control MCB tripping and trace the path.
Check for 12VDC aux. supply in EDS aux input terminal.
If 12VDC coming, EDS may be in failure. Replace the EDS.
19 In EDS “Trigger ON” in-dication not glow, when ISaver controller issue the bank ON command.
Heat sink thermostat/harmonic filter thermostat may open.
Switch off the panel, Check corresponding thermostat for NC using multimeter. If thermostats open it may due to over temperature or fault condition. After a few minutes recheck the thermostat.
If thermostat shows open, replace the thermostat
20 In EDS “Trip “indication shown.
Respective MCCB may switch OFF.NO voltage fed to thyristor module.
Thyristor may failure
Any abnormal grid fluctuation.
Check the MCCB and voltage fed to the Thyristor module.
Check the thyristor – failure replaces the thyristor.
– Page 28 –
21 DG operation not working.
DG feedback voltage fails
iSaver program setting problem
(0.8A) fuse failure
Contactor not energized
Check the DG output voltage using digital multimeter it should be 320 to 350V
Check iSaver control set up DG PF set may be Zero if it’s found Zero set 0.80 PF
Check 0.8A fuse in between Contactor coil and DG output if it is failed replace the fuse
Checks the contactor coils supply if it is healthy replace the 9A 4 pole contactor.
22 All banks turn ON even No required KVAR
Mains CT location at wrong place Check the Mains CT coil location it should be placed before iSaver panel Voltage cable which mean iSaver current also flow through that mains CT if it is wrongly located please change the CT location above mentioned place.
