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ENCORP iSAVER DPFC 450, Operating Manual, Page: 1 / 28

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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

Summary of Contents for iSAVER DPFC 450

Page 1: ...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 info encorp co nz www encorp co nz ...

Page 2: ...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 ...

Page 3: ...ing 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...

Page 4: ...ncrease 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 tem...

Page 5: ...ctrical 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...

Page 6: ... feature iSaver internal key component functional analysis and status display iSaver Monitor Displays main and ISaver panel parameters locally and remotely DG operation Dedicated PF setting for DG operation Displayed Data PF kVA kVAh kW kWh kVAr kVArh Hz V THD I THD Main Protection Short circuit and Over load protection MCCB 600A 50KA 3Pole Bank Protection Short circuit and Over load protection MC...

Page 7: ...ature iSaver internal key component functional analysis and status display iSaver Monitor Displays main and ISaver panel parameters locally and remotely DG operation Dedicated PF setting for DG operation Displayed Data PF kVA kVAh kW kWh kVAr kVArh Hz V THD I THD Main Protection Short circuit and Over load protection MCCB 1000A 50KA 3Pole Bank Protection Short circuit and Over load protection MCCB...

Page 8: ...ze 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 ...

Page 9: ...r 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 ...

Page 10: ...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 importan...

Page 11: ...f 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 ...

Page 12: ...uring 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 sele...

Page 13: ...r METERING SETUP NEW 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 ...

Page 14: ...rt 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 pr...

Page 15: ...gs 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 ID 001 In order to get on line monitoring active it is essential to set the device ID Press key and...

Page 16: ...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 SETUP ENERGY RESET DONE ENTERED 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 remain...

Page 17: ...ct 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 indicat...

Page 18: ...rning 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 c...

Page 19: ...n ever require It recommended during installation Default Control setup Setting parameters iSaver 450 iSaver 650 EB PF Set point 1 00 1 00 DG PF Set point 0 80 0 80 Connection delay 02 0 02 0 Reconnection delay 005 005 NO of Banks 5 7 1st bank value 50 50 Operating sequence 1 2 2 2 2 1 2 2 2 2 Default Alarm setup Setting parameters iSaver 450 iSaver 650 Over voltage set 110 110 Over current set 12...

Page 20: ...lect the iSaver current display page iSAVER CURRENT A 50 0 B 50 0 C 50 0 50 0 Now press the key AUTO MAN 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 iSav...

Page 21: ... C6 100 96 C7 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 di...

Page 22: ...heck 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 2 No 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 C...

Page 23: ...ero 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...

Page 24: ... 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 Capacit...

Page 25: ...cedure 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 Malfunct...

Page 26: ...ver 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 t...

Page 27: ...n 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 t...

Page 28: ...o 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 ma...

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