Assembly Manual

ElectroFlowTM
Assembly Manual
Electenergy Technologies, Inc.

“Progress Through Innovation”
Table of Contents
Preparation ......................................................................................................................... 1
I) Introduction................................................................................................ 1
II) Codes and Requirements............................................................................ 2
III) List of Parts/Components........................................................................... 3
IV) List of Minimum Recommended Inventory .............................................. 5
V) List of Recommended Tools...................................................................... 8
K1 - Large Cabinet ............................................................................................................ 9

I) List of Parts, Components.......................................................................... 9
II) Wiring Diagram and Components Layout................................................ 13
Figure 1 - Main Terminal Block Plate Layout.............................. 13
Figure 2 - Drawer Layout ............................................................. 14
Figure 3 - Schematic for A-Series Model, 1300 Regulator .......... 15
Figure 4 - Schematic for M-Series Model, 1333 Regulator ......... 16
Figure 5 - Regulator 1300 ............................................................. 17
Figure 6 - Regulator 1333 ............................................................. 18
Figure 7 - Transformer Plate Layout ............................................ 19
III) Assembly................................................................................................... 20
Power Cables ................................................................................ 21
Installing the Regulator Panel....................................................... 23
Installing the Transformer Plate ................................................... 23
Installing the Thermocouple ......................................................... 24
Control Wiring .............................................................................. 24
Labels and Signs ........................................................................... 26
Inspection...................................................................................... 28
Fuses ............................................................................................. 28
IV) Testing and Calibration............................................................................. 29
K2 - Medium Cabinet ....................................................................................................... 30

I) List of Parts, Components and Wire/Cable Lengths................................. 30
Figure 8 - K2 Layout .................................................................... 32
Figure 9 - K2 Schematic ............................................................... 33
III) Assembly................................................................................................... 34
Hardware....................................................................................... 34
Wiring ........................................................................................... 35
Labels and Signs ........................................................................... 36
Inspection...................................................................................... 38
IV) Testing and Calibration............................................................................. 39
K3 - Small Cabinet............................................................................................................ 40
I) List of Parts, Components and Wire/Cable Lengths................................. 40
Figure 10 - K3 Layout .................................................................. 42
Figure 11 - K3 Schematic ............................................................. 43
III) Assembly................................................................................................... 44
Hardware....................................................................................... 44
Wiring ........................................................................................... 45
Labels and Signs ........................................................................... 46
Inspection...................................................................................... 48
Appendix........................................................................................................................... 50
Resistor Color Codes ............................................................................................ 50
Typical Recommended Ratings of Cables and Protected Devices ....................... 51
Cable Specification Table ..................................................................................... 53
Cabinet Construction Drawings............................................................................ 54
Figure 12 - K1 Cabinet ................................................................. 54
Figure 13 - K1 Cabinet Lower Door............................................. 55
Figure 14 - K1 Cabinet Upper Door ............................................. 56
Figure 15 - K1 Cabinet Drawer .................................................... 57
Figure 16 - K1 Cabinet Regulator Panel Rear View .................... 58
Figure 17 - K1 Cabinet Control Transformer Plate ...................... 59
Figure 18 - K1 Cabinet Main Terminal Block Plate..................... 60
Figure 19 - K2 Cabinet ................................................................. 61
Figure 20 - K2 Cabinet Door Panel .............................................. 62
Figure 21 - K3 Cabinet ................................................................. 63
Figure 22 - K3 Cabinet Door Panel .............................................. 64
Example Specification Sheet ................................................................................ 65
Example Job Sheets .............................................................................................. 66
ElectroFlowTM Assembly Manual
Preparation
I- Introduction
This manual covers the assembly of the K1, K2, and K3 cabinets. All instructions
should be read carefully before starting.
Particular care should be taken to read and understand all of the relevant codes
and requirements provided in section II.
An overall list of parts/components required, for every model, is provided in

section III.
A list of the minimum inventory is provided in section IV. It lists the

recommended minimum number of parts/components that should be kept in stock.
A list of the minimum tools required is provided in section V.
4
II- Codes and Requirements
The National Electrical Code® Handbook is published by the National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269-9990, USA.
The following references should be read and used as minimum guidelines.
Article 110 - Requirements for Electrical Installations

110-5 - Conductors
110-4 - Electrical Connections
110-21 - Marking
Article 240 - Over current Protection

G. Circuit Breakers
240-80 - Method of Operation
240-81 - Indicating
240-82 - Nontamperable
240-83 - Marking
Article 310 - Conductors for General Wiring

(Also, see "Typical Recommended Ratings of Cables and Protected
Devices" and "Cable Specification Table" in the Appendix)
310-11 - Marking
Article 373 - Cabinets and Cutout Boxes

373-4 - Unused Openings
373-6 - Deflection of Conductors
373-7 - Space in Enclosures
373-10 - Material
Article 460 - RC Cans

460-2 - Enclosing and Guarding
460-8 - Drainage of Stored Charge
460-8 - Conductors
460-12 - Marking
Article 470 - Resistors and Reactors

470-2 - Location
470-3 - Space Separation
5
III- Parts list
Cabinets
Large, part # K1, for Automatic Units, A-series
Medium, part # K2, for Manual units, M-series
Small, part # K3, for manual units, M-series
Cables & Connectors

#4, THHN, THWN, MTW, AWM cable roll (Black, Red, Blue)
#18, TFFN, MTW, AWM cable roll (Black, Red, Blue)
#8, Spade tongue connector with flange
#4, Vinyl Insulated Butt connectors
Cable Ties
8" Plastic Cable Ties
RC Can/Resistor Cans
RC212 (240V) - Only, if specified.
Conduit
½" Flexible plastic conduit
Conduit Nipples
1" Conduit Nipples
Contactor
CR3, Change-Over Reactive Contactor with transient suppression.
Current Transformers (CT)

External CT’s – CTX, 600/5, 1000/5, 2000/5, 3000/5
Internal CT – CTN, 500/5
Fans
Muffin fan 120cfm (cubic feet per minute) - for normal climate Muffin fan
250cfm (cubic feet per minute) - for hot climate
6
Fuse
Midget (JJN3, two needed/K1 cabinet), part # F3
Fuse Block
Small (one needed/K1), part # FB1
Metal Oxide Varistors (MOV's) – MOV's rated at Line-to-Neutral voltage+,

refer to specification sheet, and can be assembled per drawing.
Reactor- Variable Non-Saturable Zigzag

VXL- To be used for voltages up to 650 V.
VZ2- To be used for voltages up to 250 V.
VZZ- To be used for voltages from 300 V to 500 V.
VZ6- To be used for voltages from 300 V to 650 V.
Regulator
Model 1333M, for A-series.
Model 1333A, for A-series.
Terminal Block
Large (For K1 cabinet), part # TB500
Medium (For K2 cabinet), part # TB175
Small (For K3 cabinet), part # TB100
XFMR plate (two phase, one needed/K1), part # TB20
Thermal Switches
c
Rated at 90ْ , for use with variable non-Saturable Zigzag reactor
c
Rated at 40ْ , for use with intake/exhaust fan(s)
Tie Pads
Adhesive square Tie Pads (for holding cable ties in-place).
Transformers (Monitoring/Control)
250 VA, single-phase, Supply Voltage/115V, for use in K1 cabinet.
50 VA, single-phase, Supply Voltage/115V, for use in K2, and K3 cabinets.
7
IV- Recommended Inventory List
Qty Part Description

Cabinet
3 Large, part # K1, for Automatic Units, A-series
5 Medium, part # K2, for Manual units, M-series
10 Small, part # K3, for manual units, M-series
Cables & Connectors
1 Roll #4, THHN, THWN, MTW, AWM cable roll (Black, Red, Blue)
1 Roll #18, TFFN, MTW, AWM cable roll (Black, Red, Blue)
Box #8, Spade tongue connector with flange
Cable Ties
Pack 8" plastic Cable Ties
RC Can/Resistor Cans
50 RC212 (240V) - Only if required in your territory.
Contactor
12 CR3 – Change-Over Reactive Contactor, with transient suppression.
Current Transformers (CTN)
15 Internal 500/5(quantity of three per each K1 cabinet).
8
Qty Part Description
Current Transformers (CT)
3 External 600/5 (For Auto ElectroFlow), part # CTX1
Fan (muffin type)
5 Muffin fan 120cfm (cubic feet per minute) - for normal climate
5 Muffin fan 250cfm (cubic feet per minute) - for hot climate
Fuse
6 Midget (JJN3, two needed/K1 cabinet), part # F3

Fuse Block
3 Large (one needed/stage), part # FB100
3 Small (one needed/K1), part # FB3
Metal Oxide Varistors (MOV's)
Box MOV's rated at supply voltage, refer to the specification sheet.
Variable Non-Saturable Zigzag Reactors
5 VXL
3 VZ2
3 VZZ
2 VZ6
Regulator
3 Model 1333A
3 Model 1333D
3 Model 1333Z
Split Bolt Connectors
Box Insulated Butt Connectors suitable for #4 AWG cable
Terminal Block
2 Large (For K1 cabinet), part # TB500
3 Medium (For K2 cabinet), part # TB175
5 Small (For K3 cabinet), part # TB100
2 XFMR plate (two phase, one needed/K1), part # TB20
Thermocouple (for muffin fan)
10 Thermocouples (rated for 38 degrees Celsius)
Tie Pads
Box Adhesive square Tie Pads (for holding cable ties down)
Transformer (Control)
2 Transformer (XFMR), single phase, line voltage/120V
9
V) List of Recommended Tools
Crimping Tool
Cable Tie gun
Insulation strippers
LCR Meter
Screwdrivers
Small ratchet socket set
Soldering Iron Set
Spanners
Torque Wrench
Voltage-Ohm-Meter (V-O-M)
Wire/cable cutters
10
K1 - Large Cabinet
Before you assemble an automatic ElectroFlowTM A-Series using the K1 cabinet, you should
thoroughly familiarize yourself with all stages of the assembly, the items, and their quantities
required. Some methods and components required may not apply to all countries where
ElectroFlow systems are constructed.
I) List of Parts, Components and Wire/Cable Lengths
Cabinet
Large, part # K1, for Automatic Units, A-series
Cables & Connectors

#18, TFFN, MTW, AWM cable roll (Black, Red, Blue)
#4, Vinyl Insulated Butt connectors
Cable Ties
8" plastic Cable Ties
RC Cans
RC212 (240V) - Only if required in your territory.
Conduit
½" Flexible plastic conduit
Conduit Nipples
1" Conduit Nipples
Contactor
CR3 – Change-Over Reactive Contactor
Current Transformer (CT)

Internal 500/5 (For Auto EF, three/K1 cabinet), part # CTI, for special applications.
Fan
Muffin fan 120cfm (cubic feet per minute) - for normal climate.
Muffin fan 250cfm (cubic feet per minute) - for hot climate.
11
Fuse
Midget (JJN3, two needed/K1 cabinet), part # F3
Fuse Block
Small (one needed/K1), part # FB3
Metal Oxide Varistors (MOV's)

MOV's rated at Line-to-Neutral voltage+, refer to specification sheet, and can be
assembled per drawing.

Regulator
Model 1333M, for A-series.
Model 1333A, for A-series.
Relay- Time-Delay
Model CR-100, for M-series, or special A-series applications..
Terminal Block
Large (For K1 cabinet), part # TB500
XFMR plate (two phase, one needed/K1), part # TB20
Thermocouple (for muffin fan)

Thermocouples (rated for 40 degrees Celsius)
Tie Pads
Adhesive square Tie Pads (for holding cable ties down)
Transformer (Control)
Transformer (XFMR), single phase, line voltage/120V
12
Wire Cable Length Chart for K1
Code Cable Type Color Length Nº Req'd Location

K1.1 #8 Red 17" – 12.5" 1/Can RC cans – VZZ,VZ2,VZ6 Reactor
K1.2 #8 Blue 24" – 18.5" 1/Can RC cans - VZZ,VZ2,VZ6 Reactor
K1.3 #8 Black 18" – 11.5" 1/Can RC cans - VZZ,VZ2,VZ6 Reactor
K1.4 #8 Red 20.5" - 15" 1/Can RC cans - VXL Reactor

K1.5 #8 Blue 19" – 13.5" 1/Can RC cans - VXL Reactor
K1.6 #8 Black 25" – 19.5" 1/Can RC cans - VXL Reactor
K1.7 #8 Red 7" - 12.5" 1/Can RC cans - Air Core Reactor

K1.8 #8 Blue 8" - 13" 1/Can RC cans - Air Core Reactor
K1.9 #8 Black 9" - 15" 1/Can RC cans - Air Core Reactor
K1.10 #4 Red 23" 1/Stage VZZ,VZ2,VZ6 Reactor - Contactor

K1.11 #4 Blue 20" 1/Stage VZZ,VZ2,VZ6 Reactor - Contactor
K1.12 #4 Black 18" 1/Stage VZZ,VZ2,VZ6 Reactor - Contactor
K1.13 #4 Red 12" 1/Stage VXL Reactor - Contactor

K1.14 #4 Blue 14" 1/Stage VXL Reactor - Contactor
K1.15 #4 Black 16" 1/Stage VXL Reactor - Contactor
K1.16 #4 Red 8" 1/Stage Contactor - Breaker

K1.17 #4 Blue 8" 1/Stage Contactor - Breaker
K1.18 #4 Black 8" 1/Stage Contactor - Breaker
K1.19 #4 Red 63" 1/Stage 1/ Breaker-Terminal

K1.20 #4 Blue 61" 1/Stage 1/ Breaker-Terminal
K1.21 #4 Black 59" 1/Stage 1/ Breaker-Terminal
13
K1.37 #12 Blue 21" 1/K1 TB20 - XFMR Primary
K1.38 #12 Black 21" 1/K1 TB20 - XFMR Primary
K1.39 #12 Blue 35" 1/K1 XFMR primary to Regulator BL
K1.40 #12 Black 35" 1/K1 XFMR Primary to Regulator CL
K1.41 #12 Red 42" 1/K1 TB20 - Regulator K
K1.42 #12 Red 42" 1/K1 TB20 - Regulator L
K1.43 #12 Blue 5.25" 1/K1 XFMR’s secondary to Fuse Block
K1.44 #12 Black 5.5" 1/K1 XFMR’s secondary to Fuse Block
K1.45 #12 Red 7" 1/MOV MOV to Phase A - Terminal
K1.46 #12 Blue 8.5" 1/MOV MOV to Phase B - Terminal
K1.47 #12 Black 10" 1/MOV MOV to Phase C - Terminal
K1.48 #12 Black 3" 2/MOV MOV Jumpers
K1.49 #12 Black 5" 1/MOV MOV to XFMR Plate - Ground
K1.50 #18 Black 41" 1/K1 C Fuse Block - Regulator Cx
K1.51 #18 Blue 41" 2/K1 B Fuse Block - Regulator Bx
K1.52 #18 Blue 61" 1/K1 Common – Fuse to Contactor Stage 1
K1.53 #18 Blue 18" 1/K1 Common -Contactor Stage 1- Stage 2
K1.58 #18 Black 14" 1/K1 C Fuse Block - Fan
K1.59 #18 Red 14" 1/K1 A1 - Stage 1 to Fan
K1.60 #18 Black 100" 1/K1 Regulator - Thermocouple
K1.61 #18 Black 10" 1/K1 Thermocouple - Contactor 1 – A1
K1.62 #18 Black 78" 1/K1 Regulator - Contactor 2 - A1
K1.67 #18 Red Sized to Fit 1/K1 Regulator - Internal CT
K1.68 #18 Blue Sized to Fit 1/K1 Regulator - Internal CT
K1.69 #18 Black Sized to Fit 1/K1 Regulator - Internal CT
K1.70 #18 White Sized to Fit 3/K1 Regulator - Internal CT
K1.71 #4 Black 66" As specified 3 Turn Air core Reactor
K1.72 #4 Red 66" As specified 3 Turn Air core Reactor
K1.73 #4 Blue 66" As specified 3 Turn Air core Reactor
14
II) Assembly
1) All wires and cables should be measured and cut before assembly starts. A list of
wire/cable lengths is given in section-I (K1.1 thru K1.74). Turns (K1.71 Thru
K1.79) should be pre-assembled as per instructions in Installing Air Core
Reactors: #22.
2) Collect and prepare all parts/components.
4) Begin assembly by removing the Main Terminal Block Plate and the Transformer
Plate from the cabinet.
5) Attach the Main Terminal Block (TB500) to the plate using the proper size bolts,
lock washers, and nuts, ensuring that it is facing the proper direction.
MOV Block
Terminal
Block
15
6) Install the M.O.V. (Metal Oxide Varistor) Box closest to the main terminal block
and connect the corresponding phases (A, B, and C) of the M.O.V Box to that of
the Main Terminal block as shown. The Ground terminal of the M.O.V Box
should be secured to the ElectroFlow cabinet to serve as the Ground. Wire lengths
for the MOV are in section-I parts list (K1.45 thru K1.49). Construct the MOV
and attach as shown:.
MOV
Block Connect
to Phase A
Connect
to Phase B
Connect
to Ground
Connect
to Phase C
7) Re-attach the completed Main Terminal Block Plate to the inside of the cabinet
remembering to ground to the upper left hand fastening bolt as shown.
16
7) Installing the Muffin Fan
Bolt the muffin fan onto its location inside the cabinet on the top left hand vent.
The fan should already have two wires cut to length (K1.58, K1.59) and attached
to its two terminals. Black is to be connected to the C-Phase of the Fuse Block
and Red is to be connected to A1 on the first stage contactor. This connection will
be completed during the Control Wiring phase of assembly.
Note: For normal climates, ElectroFlowTM may be equipped with the

standard features; you may use a muffin fan rated at 120cfm (cubic feet per
minute). For hotter climates, ElectroFlowTM may need to be equipped with
one or more of the Optional Features; you may use a muffin fan rated at 250
cfm or higher and may require a thermocouple.
17
9) Assemble the Transformer Plate outside the cabinet.
10) Attach the four-slot Terminal Block (TB20) to the Transformer Plate using the
proper size bolts, lock washers, and nuts. Two terminals are for voltage
connections of phases B and C and the remaining two are for the external phase-A
CT (K & L on Regulator).
11) Attach the fuse block (FB1) to the Transformer Plate using the proper size bolts,
lock washers and nuts.
12) Attach the control transformer (single phase, line voltage/120V) to the
Transformer Plate (primary terminals pointing up as shown) using the proper size
bolts, lock washers and nuts.
13) Re-attach the Side Transformer Plate to the inside of cabinet.
Control
XFMR
FB 1
TB 20
18
14) Installing the Regulator Panel
Install type 1333A or 1333M Regulator equipped with the S.D.F. (Self Diagnostic
Feature), which includes the fastening apparatus.
19
Drawer Assembly
15) A maximum of 2 stages fit in each drawer. Please note that ODD numbered
stages(Stage#1, Stage#3, and Stage#5) must be installed on the right side of the
drawers, and EVEN numbered stages(Stage#2, Stage#4, Stage#6) must be
installed on the left side of the drawers.
16) Assemble the last stage specified first and work backwards, i.e. for a four stage
unit, start with the second drawer to assemble the third and fourth stages.
17) Assemble and attach the breakers and contactors to the drawer outside the
cabinet. In the case of stages 5 & 6 attached the RC Cans while drawer is outside
the cabinet as well.
18) The Breakers are to be installed on the front panel of the drawer - one on the
center left and one on the center right when two stages are in the drawer, or one
on the center right when one stage is in the drawer. Use bolts, which are provided
to secure them.
20
Stage 2 Stage 1
Stage 4 Stage 3
19) The contactors (CR3) are to be installed on the front panel of the drawer - one on
the outside left and one on the outside right, when two stages are in the drawer, or
one on the outside right when one stage is in the drawer. Use bolts, lock washers,
and screws to secure the contactors.
20) Replace the drawer and fasten the specified number of RC cans to the drawer. The
RC cans are to be secured to the drawer with a bolt from above and lock washers
and nuts underneath.
21
RC Cans
VXL VZZ
Installing Reactors
21) Once the drawer is replaced, all VXL and Air Core Reactors can be installed.
However, when large reactors (VZZs, VZ2s and VZ6s) are specified, they should
be installed, after control wire in order to simplify the control wire installation.
22) There are two types of reactors used:

Air core - These are turns of cables bundled together in a 5 to 6-inch diameter:
These require insulated butt connectors to fasten to #8 wire cables and hence to
the RC Cans.
22
Air Core Reactors:
If air core reactors (Turns) are specified (K1.71 Thru K1.73 – 3 Turn) (K1.74
Thru K1.76 – 5 Turn) (K1.77 Thru K1.79 – 0 Turn), make sure that the cable
used is #4 AWG, and the diameter of turns does not exceed 6" (150 mm). They
should be attached to the #8 AWG RC Can wires (K1.7, K1.8, K1.9) using
insulated butt connectors and the entire turn assembly should then be installed and
attached to the contactors & RC Cans as a harness.
5T
Air Core
3T
Air Core
These lengths of #8 AWG RC Can cable should have a #8 Spade-Tongue-

Connector with Flange on one end, which is provided with the RC can. The spade
connector ends go on the RC cans with the colors from front to back being Red,
Blue, Black (phases A, B and C). Use a lock washer and nut (also provided) to
secure each spade connector to the RC cans. Tighten the cables to16 inch-lbs.
Secure the coil turns using plastic cable ties and anchor pads where needed.
23
Iron Core Reactors:
23) If iron core reactors are specified, secure them to the drawer using bolts from
above and lock washers and nuts below. As stated, when a VZZ, VZ2 or VZ6 is
specified, this should be one of the last steps in assembly. However, when VXL
reactors are specified, they should be installed at the time of drawer assembly.
VXL
VZZ
RC Can Wire: K1.1, K1.2, K1.3 for Large Iron Core reactors (VZ6, VZZ & VZ2).
K1.4, K1.5, K1.6 for a Small Iron Core reactor (VXL).
These lengths of #8 AWG RC Can cable should have a #8 Spade-Tongue-

Connector with Flange on one end, which is provided with the RC can. The spade
connector ends go on the RC cans with the colors from front to back being Red,
Blue, Black (phases A, B and C). Use a lock washer and nut (also provided) to
secure each spade connector to the RC cans. Tighten the cables to16 inch-lbs. and
attach to the VXL. The cables for VZZs, VZ2s and VZ6s and VXLs are specified
below.
24
RC Can to Reactor:
Connect the cables for each phase of the specified number of RC cans (up to four
depending on RC Can rating) to the corresponding specified terminal on the
reactor and firmly tighten the cable. The phases are from left to right in ports 2, 4,
& 6 - Black, Red, Blue (phases C, A and B). This is because the ports for the in
and out on the reactor are as follows. Remember to always firmly fasten the
secondary nut, provided with the box terminals on the Iron Core Reactors to
ensure it does not become loose during shipping.
RC Cans
VXL VZZ
Iron Core Reactor Ports: From left to right…
• Port 1 is Phase A in (contactor to Reactor), using Red #4 AWG wire
• Port 2 is phase C out (RC Can to Reactor), using Black #8 AWG wire
• Port 3 is Phase B in (contactor to Reactor), using Blue #4 AWG wire
• Port 4 is Phase A out (RC Can to Reactor), using Red #8 AWG wire
• Port 5 is Phase C in (contactor to Reactor), using Black #4 AWG wire
• Port 6 is Phase B out (RC Can to Reactor), using Blue #8 AWG wire
Reactor to Contactor Cables: K1.10, K1.11, K1.12 for (VZZ, VZ2, VZ6)
K1.13, K1.14, K1.15 for (VXL)
25
VXL
#8x2
#4x1
#4x1
#8x2 VZ6,
#8x2
#4x1
#4x1
VZZ,
VZ2.
#8x2
#8x2
#4x1
#4x1
#8x2
Front View
Terminals left to right
2 Blue #8 cables to RC Cans
1 Black #4 cable from contactor
2 Red #8 cables to RC Cans
1 Blue #4 cable from Contactor
2 Black #8 cables to RC Cans

1 Red #4 cable from Contactor
26
Now that the drawers and plates have been assembled and replaced in the cabinet,
you are ready to complete the assembly.
Power Cables:
24) When connecting the appropriate wires and cables, per the Specification Sheet for
each ElectroFlowTM, have the schematics and layout diagram handy. The
schematics for the K1 are given in the previous section.
25) Cable/wire lengths are provided in Section-I (K1.19 Thru K1.36)
26) Terminal wires should be fastened together by stage as specified. They should be
fastened flush on one end to be connected to the breakers and on the other end
should have a 2 inch gap between the three on the other end. This may require
cutting some off the terminal block ends of the cable harness in order for the
cables to insert uniformly into the terminal block. This is because the lengths will
not always line up properly once fastened into a 3 cable harness. However there is
sufficient length included for this.
27) Connect #4 AWG wire cable that goes from the Breakers (from left to right - Red,
Blue, Black or Phase A, B, C), through the lower front and side openings of the
drawer, up the left corner of the cabinet to the Main Terminal Block (TB 500).
The cables should rest firmly and uniformly up the left corner of the cabinet and
should have a horseshoe of slack for cosmetic purposes as well as functionality
(retracting drawer for maintenance) and then insert and tighten into the Main
Terminal Block (from top to bottom – Red, Blue, Black or Phase A, B, C) to 25
inch-lb.
28) Use plastic cable ties to tie cables down wherever required.
The correct cables to use are:

K1.19, K1.20, K1.21 for Stage 1
K1.22, K1.23, K1.241 for Stage 2
K1.25, K1.26, K1.27 for Stage 3
K1.28, K1.29, K1.30 for Stage 4
K1.31, K1.32, K1.33 for Stage 5
K1.34, K1.35, K1.36 for Stage 6
Retighten the screws of the ports on the Breakers to 25 inch-lb.

You are now ready to install the remaining control wiring.
27
Control Wiring:
29) When connecting the control wires, have the schematics and layout diagram
handy.
30) There are 2 small access holes just behind the contactor auxiliaries on the face of
the drawers. All control wires from the contactors to various terminals should be
strung through these holes and out of view as follows.
31) Using the #12 AWG wire with spade-tongue-connectors w/flange on one end to
connect (up, and behind the transformer plate) (K1.37 Thru K1.40) Tighten the
connections on the transformer and then connect the 2 line voltage wires of the
transformer to VB (Blue) and VC (Black) terminals of the Terminal Block (TB20) on
the transformer plate and tighten the wires to 25 inch-lb. Then connect the 2 BL
and CL wires to the regulator and tighten the wires to 25 inch-lbs.
32) Using the #12 AWG wire (K1.43, K1.44) with spade-tongue-connector w/flange
on one end, connect each terminal of the secondary side (120V) of the
transformer to its corresponding terminal on the fuse block. Color-coding of the
wires are Blue for the B-phase and Black for the C-phase. Tighten the
connections to 25 inch-lbs.
33) Using the #12 AWG wire (K1.41, K1.42), connect ports K & L from the regulator
to A and A on the Terminal Block (TB-20). Tighten the connections to 25 inch-
lbs.
34) Using #18 AWG control wire (K1.41, K1.42), connect the 2 Blue wires to BX 1
& 2 and the Black wire to CX on the regulator. Connect the BX wires down and
behind the XFMR plate to B on the Fuse Block and the CX wire down and behind
the XFMR plate to C on the Fuse Block.
35) Using Blue #18 AWG wire (K1.52 Thru K1.57), connect the Contactor common
(A2 to A2), stage to Stage, from stage 6 backwards. The path ends with A2 on
stage1 to C on Fuse Block.
36) Using #18 AWG wire (Black) and once again working backwards from stage 6 to
stage 2 connect the Contactors (A1), directly to the Regulator in the designated
terminals as shown (Using K1.45 Thru K1.49) for each of the specified stages.
Stage 1 requires a thermocouple installed in series between contactor and
regulator.
.
28
Installing Thermocouple:
37) Using #18 AWG wire (Black)…whenever one of the Large Iron Core Reactors
(VZ6, VZZ & VZ2) is used, you MUST install a thermocouple switch in series
between A1 of stage 1 and stage 1 on the regulator so that whenever temperature
exceeds that of the thermal switch rating it will open circuit and protect the
reactor. The thermal switch itself must be inserted between two reactor windings
(as shown) to monitor reactor coil temperature, and the thermal switch’s two
wires must be secured to one of the reactor posts (wing nut post under the top
plate of the reactor). Make sure that there is sufficient wire to allow the thermal
switch to be securely placed at sufficient depth between the two reactor windings
(coils). Fasten the switch in place with a piece of electrical tape as shown.
Thermal
Switch
Installing Secondary Thermocouple: if required…

38) For abnormal climates, a secondary thermocouple may be specified for an
additional muffin fan and must be connected in series with one of the supply leads
to the fan. The thermocouple is physically attached to one of the mounting bolts
for the transformer plate on the left hand side of the cabinet. It is attached on the
backside; behind the transformer plate. It is recommended that the thermocouple
be connected in series with the N.O. (Normally Open) contacts/terminals on the
auxiliary contacts of the first stage contactor. This is done so that if the first stage
29
of the ElectroFlowTM is activated, the fan will be energized as well.
You are now ready to install the large reactors and remaining #4 reactor cables.
39) Place the Reactors in the drawer and secure them to the drawer using bolts from
above and lock washers and nuts below.
40) Connect #4 AWG cable (K1.10 Thru K1.12) for (VZZ, VZ2 & VZ6) of the
correct color (from left to right - Red, Blue, Black or Phase A, B, C) from the
terminal on each phase of the reactor (Red, Blue, Black or Terminal 1, 3, and 5 on
the Reactors), through the access hole on face of drawer, to its corresponding
terminal on the contactor. Tighten contactor terminals to 25 inch-lb.
41) Connect #4 AWG cable (K1.16 Thru K1.18) between the Breakers (from left to
right - Red, Blue, Black, or Phase A, B, C) and the corresponding contactor for
that stage. Tighten the fuse connections to 25 inch-lb. Tighten contactor terminals
to 25 inch-lb.
30
Labels and Signs:
48) Label all wires and cables.

49) Attach Identification plate on the outside of the cabinet, as required by your
local electrical codes and requirements, such as:
50) Attach warning signs to outside of the cabinet, as required by your local
electrical codes and requirements, such as:
31
51) Attach specification label on inside of the cabinet, as required by your local
electrical codes and requirements, such as:
Inspection
52) Check all items for correct type and placement.
53) Check all wires and cables for position, size, color, and labeling.
54) Check to make sure that the cables are connected to their respective
parts/components.
55) Check that the cables are securely fastened and that screws/nuts/terminals are
tightened to the correct tension.
NOTE: Loose cables/wires are the number problem experienced after activation
of ElectroFlow. Make sure that cables/wires are securely fastened!!!
56) Check that all wires and cables are bundled neatly using plastic cable ties and tie
pads and placed out of view. Ensure that control wires are wrapped with conduit
from the regulator to the cabinet for aesthetic purposes.
Fuses
57) Install the two fuses (part # F3), rated at 3A each (as specified) in the Fuse Block
(part # FB3) on the transformer plate.
32
IV) Testing and Calibration
1) Using an analog Voltage-Ohm-Meter (V-O-M), set the meter’s selector switch to
Ohm. At the following test locations:
a) Fuse Blocks
b) Load side of each stage contactor
Check to make sure that no short circuit exists between any of the phases (phases
A, B and C), as well as between any of the phases to Ground. This means the
check should be done at the line side (supply side) of each inductor/reactor,
whether iron core or air core.
If you observe the slightest meter movements, whilst taking these readings(with
the exception of the RC can deflection/movement of the needle for the
charging/discharging), stop the inspection and locate cause of the short circuit.
Correct/eliminate the problem and repeat the tests.
You should use an insulation tester device, to apply the voltage required by your
local electrical codes, between each phase of Reactor/Inductor to Ground
(Reactor/Inductor body). Similarly, the same insulation testing can be done for
the RC cans, and between each phase of each RC can to Ground(RC Can body).
2) Using a Voltage-Ohm-Meter (V-O-M), set the meter selector switch to Ohm.

Check phase-to-phase readings at the terminal block, phase A and phase B (Red
and Blue cables), phase B and phase C (Blue and Black cables), and phase C and
phase A (Black and Red cables).
In all the three cases, you should note a deflection/movement of the needle on the
analog meter, and increasing readout on digital meters. In the case of both meters,
you should observe an upward charging action, followed by a downward
discharging action. If such a condition is not observed, examine your connections,
correct as needed, and repeat the tests.
33
K2 - Medium Cabinet
Before you assemble a semi-manual ElectroFlowTM M-Series using the K2 cabinet, you
should thoroughly familiarize yourself with all stages of the assembly, the items, and
their quantities required.

Cabinet- Medium, part # K2, for Manual units, M-series
Cables & Connectors

Cable Ties- 8" plastic Cable Ties
CapTel 618
Enunciator LED lights, for continuous monitoring of each phase proper operation.
RC Can/Resistor
RC212 (240V) – Only, if required in your territory


Regulator
CR-100, variable time-delay relay with special settings.
Terminal Block
Medium (For K2 cabinet), part # TB175
34
Wire Cable Length Chart for K2:


K2.7 #4 Red Sized to Fit As specified 0 Turn Air core Reactor

K2.8 #4 Blue Sized to Fit As specified 0 Turn Air core Reactor
K2.9 #4 Black Sized to Fit As specified 0 Turn Air core Reactor
K2.10 #8 Red 20.5" - 15" 2/K2 RC cans - Iron Core Reactor

K2.11 #8 Blue 19" – 13.5" 2/K2 RC cans - Iron Core Reactor
K2.12 #8 Black 25" – 19.5" 2/K2 RC cans - Iron Core Reactor
K2.13 #8 Red 12" 2/K2 RC cans-3&5 Air core Reactor

K2.14 #8 Blue 12" 2/K2 RC cans-3&5 Air core Reactor
K2.15 #8 Black 12" 2/K2 RC cans-3&5 Air core Reactor
K2.16 #8 Red Sized to Fit 2/K2 RC cans-0 Air core Reactor

K2.17 #8 Blue Sized to Fit 2/K2 RC cans-0 Air core Reactor
K2.18 #8 Black Sized to Fit 2/K2 RC cans-0 Air core Reactor
K2.19 #4 Red 36" 1/K2 Reactor - Terminal Block

K2.20 #4 Blue 34" 1/K2 Reactor - Terminal Block
K2.21 #4 Black 32" 1/K2 Reactor - Terminal Block
K2.22 #4 Red 25" 1/K2 H1-XFMR to Terminal-Phase A

K2.23 #4 Black 24" 1/K2 H3-XFMR to Terminal-Phase C
K2.24 #4 Red 4" 1/K2 X1- XFMR to A1-CR100
K2.25 #4 Black 4" 1/K2 X2- XFMR to A2-CR100
K2.26 #4 Red 20.5" 1/K2 X1-XFMR to A2-Contactor

K2.27 #4 Black 19" 1/K2 X1-XFMR to CC-CR100
K2.28 #4 Black 27" 1/K2 NO-CR100 to A1-Contactor
35
II) Wiring Diagram and Components Layout
36
III) Assembly
Hardware:
1) All wires and cables should be measured, cut and the ends stripped of insulation
before assembly starts. A list of wire/cable lengths is given in section-I. Turns
should be pre-assembled as per instructions in Air Core Reactors.
2) All components are installed inside the cabinet.
3) The terminal block (TB175) is installed on the rear panel at the upper right of the
cabinet in the designated holes. Use bolts, nuts and lock washers to secure the
terminal block.
4) The Control Transformer is to be installed on the right, side panel of the cabinet
(left of terminal block) with the designated holes. Use bolts, nuts and lock
washers to secure it.
5) The contactor is to be installed in the center of the back panel of the cabinet in the
designated holes. Use bolts, nuts and lock washers to secure it.
37
6) If iron core reactors are specified, secure them to the upper left rear panel using
bolts from outside and nuts and lock washers on the inside.
7) If air core reactors (K2.1 thru K2.9) are specified, make sure that the diameter of
turns does not exceed 6" (150 mm). The coils should be made from #4 AWG
cable with the turns and diameters provided on the Specification Sheet for each
ElectroFlowTM. Secure the RC Can wires (K2.13 thru K2.18) to the reactors
using #4 Butt connectors and #8 Spade-Tongue-Connector with Flange on one
end, which is provided with the RC can. The spade connector ends go on the RC
cans with the colors from front to back being Red, Blue, Black (phases A, B and
C). Use a lock washer and nut (also provided) to secure each spade connector to
the RC cans. Tighten the cables to the RC Cans at16 inch-lbs and attach. Secure
the coil turns using plastic cable ties and tie pads where needed.
8) Fasten the specified number of RC cans (between two and four) at the bottom of
the cabinet. The RC cans are to be secured with a bolt from below and lock
washers and nuts inside.
38
9) The CTs should be installed during wiring. The CT is connected to a wire with an
LED light. This LED light is to be inserted through the opening of the faceplate
and connected to the plastic cover on the outside of the cabinet. The LED light is
designed to clip into the plastic cover.
Wiring:
schematics and cabinet layout drawings for the K2 are given in the previous
section (Section II - Wiring diagram and components layout).
11) Cable/wire cable lengths are provided in Section-I and are referred to by codes of
the form: (K2.1), (K2.2), ...

Air core: These require split bolt connectors.
Iron core: These have box terminals.
The RC cans on the LHS (Left Hand Side) of the cabinet are connected to the Iron
Core Reactor and the RC cans on the RHS (Right Hand Side) of the cabinet are
connected to the Air core Reactor.
Connect the cables for each phase of the specified number of RC cans (up to two)
to the corresponding specified terminal on the reactor and firmly tighten the
cable. The phases are from left to right in ports 2, 4, & 6 - Black, Red, Blue
(phases C, A and B). This is because the ports for the in and out on the reactor are
as follows. (Figure 9).

• Port 1 is Phase A in (Reactor to Contactor) using Red #4 AWG wire
• Port 2 is Phase C out (Reactor to RC Can) using Black #8 AWG wire
• Port 3 is Phase B in (Reactor to Contactor) using Blue #4 AWG wire
• Port 4 is Phase A out (Reactor to RC Can) using Red #8 AWG wire
• Port 5 is Phase C in (Reactor to Contactor) using Black #4 AWG wire
• Port 6 is Phase B out (Reactor to RC Can) using Blue #8 AWG wire
Refer to the diagram.
39
14) Connect #4 AWG cable (K2.19 thru K2.21) of the correct color (from left to right
- Red, Blue, Black) from the terminal on the base of each phase of the reactor to
its corresponding terminal on the terminal block (part # TB175).
Remember, for the CapTel 618 connections, to pass each of the phase-cables
through the center of its respective CT connected to the LED lights.
Now that the #4 AWG cable is installed you must now install the control wire.
15) Using #12 AWG cable with #12 Spade Flange Connectors on one end, connect
(K2.24 & K2.26) to X1 on the Control Transformer. Connect the other end of
(K2.24) to A1 on the CR-100 and connect the other end of (K2.26) to A2 on the
Contactor.
(K2.24) to A1 on the CR-100 and connect the other end of (K2.26) to A2 on the
Contactor.
(K2.25) to A2 on the CR-100 and connect the other end of (K2.27) to CC on the
CR-100.
(K2.22) to H1 on the Control Transformer. Connect the other end of (K2.22) to
Terminal Block Phase A.
19) Using #12 AWG cable with #12 Spade Flange connectors on one end, connect
(K2.23) to H3 on the Control Transformer. Connect the other end of (K2.22) to
Terminal Block Phase C.
20) Using #12 AWG cable connect (K2.28) to NO on the CR-100. Connect the other
end of (K2.28) to A1 on the Contactor.
40
If specified, connect the MOV block as shown below.
Connect
to Ground Connect
to Phase A
Connect
to Phase B
Connect
to Phase C
41
Labels and Signs:
21) Install the CapTel 618 plate with the LED display enunciator lights, when
lit, indicate status of normal operation for each phase of each stage, as
shown. In the blue arrow, the three green LED lights represent(from top to
bottom) status of Phase A, Phase B, and Phase C of stage #1 within K2.
In the Orange circle, the three red LED lights represent(from left to right)
status of Phase A, Phase B, and Phase C of stage #2 within K2 :
22) Attach warning signs to the outside of the cabinet, as required by your
local electrical codes and requirements, as shown:
42
23) Attach specification label on the inside, side panel of cabinet,
as required by your local electrical codes, such as:
Inspection:
25) Check all wires and cables for position, size, color and labeling.
CHECK THAT THE CABLES ARE CONNECTED TO THE CORRECT

PARTS.
Check that the cables are securely fastened and that screws/nuts are tightened to
the correct tension.
26) Check that all wires and cables are bundled neatly using plastic cable ties and that
they are places out of the way.
43
1) The CapTel 618 plate with the LED display enunciator lights, when lit, indicate
status of normal operation for each phase of each stage, as shown. In the blue
arrow, the three green LED lights represent(from top to bottom) status of Phase
A, Phase B, and Phase C of stage #1 within K2. In the Orange circle, the three
red LED lights represent(from left to right) status of Phase A, Phase B, and Phase
C of stage #2 within K2.

a) Fuse Blocks
b) Load side of each stage contactor

44
K3 - Small Cabinet
Before you assemble a manual/semi-manual ElectroFlowTM M-Series using the K3
cabinet, you should thoroughly familiarize yourself with all stages of the assembly, the
items and their quantities required.
Cabinet
Small, part # K3, for manual/semi-manual units, M-series
Cables & Connectors

#4, THHN (Red, Blue, Black)
#8, THHN,THWN, MTW, AWM cable roll (Red, Blue, Black)
Cable Ties
8"plastic Cable Ties
CapTel 618
Enunciator LED lights, for continuous monitoring of each phase proper operation.
RC Cans
RC212 (240V) - Only if required in your territory


Terminal Block
Small (For K3 cabinet), part # TB100
45
Wire Cable Length Chart for K3:
K3.1 #4 Black 66" 2/K3 3 Turn Air core Reactor

K3.2 #4 Red 66" 2/K3 3 Turn Air core Reactor
K3.3 #4 Blue 66" 2/K3 3 Turn Air core Reactor
K3.4 #4 Black 111" 2/K3 5 Turn Air core Reactor

K3.5 #4 Red 111" 2/K3 5 Turn Air core Reactor
K3.6 #4 Blue 111" 2/K3 5 Turn Air core Reactor
K3.7 #4 Black Sized to Fit As specified 0 Turn Air core Reactor

K3.8 #4 Red Sized to Fit As specified 0 Turn Air core Reactor
K3.9 #4 Blue Sized to Fit As specified 0 Turn Air core Reactor
K3.10 #8 Red 12" 2/K3 RC cans-3&5 Air core Reactor

K3.11 #8 Blue 12" 2/K3 RC cans-3&5 Air core Reactor
K3.12 #8 Black 12" 2/K3 RC cans-3&5 Air core Reactor
K3.13 #8 Red Sized to Fit 2/K3 RC cans-0 Air core Reactor

K3.14 #8 Blue Sized to Fit 2/K3 RC cans-0 Air core Reactor
K3.15 #8 Black Sized to Fit 2/K3 RC cans-0 Air core Reactor
K3.16 #8 Red 20.5" - 15" 2/K3 RC cans - Iron Core Reactor

K3.17 #8 Blue 19" – 13.5" 2/K3 RC cans - Iron Core Reactor
K3.18 #8 Black 25" – 19.5" 2/K3 RC cans - Iron Core Reactor
K3.19 #4 Red 36" 1/K3 Reactor - Terminal Block

K3.20 #4 Blue 34" 1/K3 Reactor - Terminal Block
K3.21 #4 Black 32" 1/K3 Reactor - Terminal Block
46
II) Wiring Diagram and Components Layout
47
III) Assembly
Hardware:
1) All wires and cables should be measured, cut, and the ends stripped of insulation
before assembly starts. A list of wire/cable lengths is given in section-I. Turns
should be pre-assembled as per instructions, if Air Core Reactors are used.
2) All components are installed inside the cabinet.
3) The terminal block (part # TB 100) is installed on the upper right rear panel of the
cabinet. Use bolts, nuts and lock washers to secure the terminal block.
4) If an Iron core reactor is specified, secure it to the upper left rear panel of the
cabinet. Use bolts, nuts and lock washers to secure the reactor.
5) If Air Core Reactors are specified, make sure that the diameter of turns does not
exceed 6" (150 mm). The coils should be made from #4 AWG cable with the
turns and diameters provided on the Specification Sheet for each ElectroFlowTM.
Secure the coil turns using plastic cable ties and tie pads where needed. These
should be installed on the upper left rear panel of the cabinet when an iron-core
reactor is not specified or the center panel of the cabinet (between the terminal
block and the reactor) when an iron-core reactor is specified.
6) The RC cans are installed on the bottom of the cabinet. The RC cans are secured
to the cabinet with a nut from above and lock washer and bolt from below.
Remember, for the CapTel 618 connections, to pass each of the phase-cables
through the center of its respective CT connected to the LED lights.
Wiring:
schematics and cabinet layout drawings for the K3 are provided in the manual.
9) Cable/wire cable lengths are provided in Section-I and are referred to by codes of
the form: (K3.1), (K3.2), ...
11) Connect the RC cans (maximum of two) with the pre-made lengths of #8 AWG
cable (K3.10 thru K3.18). These lengths of cable should have a #8 Spade-Tongue-
Connector with Flange (provided) on one end. The spade connector ends go on
48
the RC cans with the colors from front to back being Red, Blue, Black (phases A,
B and C). Use a lock washer and nut (provided) to secure each spade connector.
Tighten cables to 16 inch-lb. (see photo).

Air core: These require split bolt connectors
Iron core: These have box terminals.
Connect the cables for each phase of the RC cans (one or two as specified) to its
corresponding terminal on the reactor. The phases are from left to right in ports 2,
4 & 6 - Black, Red, Blue (phases C, A and B) (See Photo). This is because the
ports for the in and out on the reactor are as follows…
• Port 1 is Phase A in (Reactor to Contactor) using Red #4 AWG wire
• Port 2 is Phase C out (Reactor to RC Can) using Black #8 AWG wire
• Port 3 is Phase B in (Reactor to Contactor) using Blue #4 AWG wire
• Port 4 is Phase A out (Reactor to RC Can) using Red #8 AWG wire
• Port 5 is Phase C in (Reactor to Contactor) using Black #4 AWG wire
• Port 6 is Phase B out (Reactor to RC Can) using Blue #8 AWG wire
13) Connect #4 AWG cable (K3.19 thru K3.21) of the correct color (from left to right
- Red, Blue, Black) from the terminal on the base of each phase of the reactor to
its corresponding terminal on the Terminal Block (part # TB100).
49
If specified, connect the MOV block as shown below.
Connect
to Ground Connect
to Phase A
Connect
to Phase B
Connect
to Phase C
50
Labels and Signs:
14) Install the CapTel 618 plate with the LED display enunciator lights, when
lit, indicate status of normal operation for each phase of each stage, as
shown. In the blue arrow, the three green LED lights represent(from top to
bottom) status of Phase A, Phase B, and Phase C of stage #1 within K2.
In the Orange circle, the three red LED lights represent(from left to right)
status of Phase A, Phase B, and Phase C of stage #2 within K2 :
15) Attach warning signs to the outside of the cabinet, as required by your local
electrical codes and requirements, as shown:
51
16) Attach specification label on the inside, side panel of cabinet,
as required by your local electrical codes, such as:
Inspection:
18) Check all wires and cables for position, size, color and labeling.
CHECK THAT THE CABLES ARE CONNECTED TO THE CORRECT

PARTS.
Check that the cables are securely fastened and that screws/nuts are tightened to
the correct tension.
19) Check that all wires and cables are bundled neatly using plastic cable ties and that
they are places out of the way.
52
1) The CapTel 618 plate with the LED display enunciator lights, when lit, indicate
status of normal operation for each phase, as shown. In the Orange circle, the
three red LED lights represent(from left to right) status of Phase A, Phase B, and
Phase C of K3 .

a) Load side of the contactor, if contactor is used; otherwise,

b) Line side (supply side) of the reactor/inductor.

53
Appendix
Typical Recommend Ratings of Cables and Protective Devices

NOTE: If equipment KVAR is equal to or greater than 150, and it is possible that the
client may increase load in the future, it is recommended that you adequately size the cables
and MCCB/Disconnect switch for 300 KVAR, but fuse it for the exact KVAR. This
allows future expansion without major modifications or shut down!
240 VOLTS
Capacitor Rated Current Min. Copper Min. Copper Fuse Amps Disconnect MCCB
3φ- per Phase (A) Cable @ 75°C Cable @ 90°C (Time Delay) Switch (A) Size (A)
KVAR
240 Volt
25 60 #4 #4 100 100 90
30 72 #2 #4 125 200 110
35 85 #1 #2 150 200 150
40 96 #1 #2 175 200 150
45 109 1/0 1/0 200 200 200
50 120 1/0 1/0 200 200 200
60 144 2/0 2/0 250 400 225
70 169 3/0 2/0 300 400 300
75 180 250kcmil 4/0 300 400 300
100 241 400kcmil 350kcmil 400 400 400
125 301 (2)-4/0 500kcmil 500 600 500
150 361 (2)-250kcmil 2-4/0 600 600 600
200 481 (2)-400kcmil (2)-350kcmil 800 800 700
250 601 (3)-300kcmil (2)-500kcmil 1000 1000 900
300 722 (3)-400kcmil (3)-350kcmil 1200 1200 1100
54
380 VOLTS
3φ-KVAR per Phase (A) Cable @ 75°C Cable @ 90°C (Time Delay) Switch (A) Size (A)
380 Volts
25 35 #6 #8 70 70 60
30 42 #6 #6 80 80 80
35 49 #4 #6 90 90 90
40 56 #4 #4 100 100 90
45 63 #4 #2 125 125 90
50 70 #2 #2 150 150 150
60 84 #1 #2 150 150 150
70 97 #1 #2 175 175 175
75 104 1/0 #1 200 200 175
80 111 1/0 #1 200 200 200
90 125 2/0 1/0 300 300 225
100 139 2/0 2/0 300 300 300
125 174 250kcmil 4/0 400 400 300
150 209 350kcmil 350kcmil 400 400 400
200 278 (4)-4/0 500kcmil 500 500 500
250 248 (2)-200kcmil (2)-4/0 700 700 600
300 417 (2)-300kcmil (2)-250kcmil 800 800 700
55
415 VOLTS
3φ-KVAR per Phase (A) Cable @75°C Cable @90°C (Time Delay) Switch (A) Size (A)
415 Volts
25 35 #6 #8 60 60 60
30 42 #6 #6 70 70 70
35 49 #4 #6 90 90 80
40 56 #4 #4 100 100 90
45 63 #4 #2 125 125 90
50 70 #2 #2 125 125 110
60 84 #1 #2 150 150 150
70 97 #1 #2 175 175 150
75 104 1/0 #1 175 175 175
80 111 1/0 #1 200 200 175
90 125 2/0 1/0 250 250 200
100 139 2/0 2/0 250 250 225
125 174 250kcmil 4/0 400 400 300
150 209 350kcmil 350kcmil 400 400 400
200 278 (2)-4/0 500kcmil 500 500 500
250 348 (2)-200kcmil (2)-4/0 600 600 600
300 417 (2)300kcmil (2)-250kcmil 700 700 650
480 VOLTS
Capacitors Rated Current Min. Copper Min. Copper Fuse Amps Disconnect MCCB
3φ-KVAR per Phase (A) Cable @ 75° C Cable @ 90° C (Time Delay) Switch (A) Size (A)
480 Volt
25 30 #8 #10 50 60 50
30 36 #6 #8 60 60 60
35 42 #6 #6 70 100 70
40 48 #4 #6 80 100 80
45 54 #4 #6 90 100 90
50 60 #4 #4 100 100 90
60 72 #2 #2 125 200 110
70 84 #1 #2 150 200 150
75 90 #1 #2 150 200 150
80 96 #1 #2 175 200 150
90 108 1/0 #1 200 200 175
100 120 2/0 1/0 200 200 200
125 150 3/0 2/0 300 400 300
150 180 250kcmil 4/0 300 400 300
200 241 400kcmil 350kcmil 400 400 400
250 301 (2)-4/0 500kcmil 500 600 500
300 361 (2)-250kcmil (2)-4/0 600 600 600
56
600 Volts
3φ-KVAR per Phase (A) Cable @75°C Cable @ 90° C (Time Delay) Switch (A) Size
(A)
600 Volts
25 24 #10 #10 40 60 40
30 29 #8 #10 50 60 50
35 34 #8 #8 60 60 60
40 38 #6 #8 70 100 60
45 43 #6 #6 80 100 70
50 48 #4 #6 80 100 80
60 58 #4 #4 100 100 90
70 67 #2 #4 125 200 110
75 72 #2 #2 150 200 125
80 77 #2 #2 150 200 125
90 87 #1 #2 150 200 150
100 96 #0 #2 175 200 150
125 120 2/0 1/0 200 300 200
150 144 3/0 3/0 250 400 225
200 192 300kcmil 250kcmil 350 400 300
250 241 400kcmil 350kcmil 400 400 400
300 289 (2)-3/0 50kcmil 500 600 450
57
Cable Specification/Conversion Table
CONDUCTOR
SIZE
cmil mm2 STRANDING CONDUCTOR
DIAMETER
COPPER
CURRENT
area area IN INCHES 90C
12 AWG 6 530 3.31 19/.0185 0.093 30
10 AWG 10 380 5.26 19/.0234 0.117 40
8 AWG 16 510 8.37 19/.0295 0.148 55
7 AWG 20 820 10.55 19/.0331 0.166 -
6 AWG 26 240 13.30 19/.0372 0.186 75
5 AWG 33 090 16.77 19/.0417 0.209 -
4 AWG 41 740 21.15 19/.0469 0.235 95
3 AWG 52 620 26.66 19/.0526 0.263 110
2 AWG 66 360 33.62 19/.0591 0.296 130
1 AWG 83 690 42.41 19/.0664 0.332 150
1/0 AWG 105 600 53.51 19/.0745 0.373 170
2/0 AWG 133 100 67.44 19/.0837 0.419 195
3/0 AWG 167 800 85.02 19/.0940 0.470 225
4/0 AWG 211 600 107.2 19/.1055 0.528 260
250 MCM 250 000 126.7 37/.0822 0.575 290
350 MCM 350 000 177.3 37/.0973 0.681 350
500 MCM 500 000 253.4 37/.1162 0.813 430
750 MCM 750 000 380.0 61/.1109 0.998 535
1000 MCM 1 000 000 506.7 61/.1280 1.152 615
58

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ElectroFlowTM

Electenergy Technologies, Inc.

K1 - Large Cabinet ............................................................................................................ 9

K2 - Medium Cabinet ....................................................................................................... 30

An overall list of parts/components required, for every model, is provided in

A list of the minimum inventory is provided in section IV. It lists the

A list of the minimum tools required is provided in section V.

Article 110 - Requirements for Electrical Installations

Article 240 - Over current Protection

Article 310 - Conductors for General Wiring

Article 373 - Cabinets and Cutout Boxes

Article 460 - RC Cans

Article 470 - Resistors and Reactors

Cables & Connectors

Current Transformers (CT)

Metal Oxide Varistors (MOV's) – MOV's rated at Line-to-Neutral voltage+,

Reactor- Variable Non-Saturable Zigzag

Qty Part Description

6 Midget (JJN3, two needed/K1 cabinet), part # F3

I) List of Parts, Components and Wire/Cable Lengths

Cables & Connectors

Current Transformer (CT)

Metal Oxide Varistors (MOV's)

Reactor- Variable Non-Saturable Zigzag

Thermocouple (for muffin fan)

Code Cable Type Color Length Nº Req'd Location

K1.4 #8 Red 20.5" - 15" 1/Can RC cans - VXL Reactor

K1.7 #8 Red 7" - 12.5" 1/Can RC cans - Air Core Reactor

K1.10 #4 Red 23" 1/Stage VZZ,VZ2,VZ6 Reactor - Contactor

K1.13 #4 Red 12" 1/Stage VXL Reactor - Contactor

K1.16 #4 Red 8" 1/Stage Contactor - Breaker

K1.19 #4 Red 63" 1/Stage 1/ Breaker-Terminal

2) Collect and prepare all parts/components.

Note: For normal climates, ElectroFlowTM may be equipped with the

22) There are two types of reactors used:

These lengths of #8 AWG RC Can cable should have a #8 Spade-Tongue-

These lengths of #8 AWG RC Can cable should have a #8 Spade-Tongue-

2 Blue #8 cables to RC Cans

1 Black #4 cable from contactor

2 Red #8 cables to RC Cans

1 Blue #4 cable from Contactor

2 Black #8 cables to RC Cans

25) Cable/wire lengths are provided in Section-I (K1.19 Thru K1.36)

The correct cables to use are:

Retighten the screws of the ports on the Breakers to 25 inch-lb.

Installing Secondary Thermocouple: if required…

48) Label all wires and cables.

2) Using a Voltage-Ohm-Meter (V-O-M), set the meter selector switch to Ohm.

I) List of Parts, Components and Wire/Cable Lengths

Cables & Connectors

Cable Ties- 8" plastic Cable Ties

Metal Oxide Varistors (MOV's) – MOV's rated at Line-to-Neutral voltage+,

Reactor- Variable Non-Saturable Zigzag

Code Cable Type Color Length Nº Req'd Location

K2.1 #4 Red 66" As specified 3 Turn Air core Reactor

K2.4 #4 Red 111" As specified 5 Turn Air core Reactor

K2.7 #4 Red Sized to Fit As specified 0 Turn Air core Reactor

K2.10 #8 Red 20.5" - 15" 2/K2 RC cans - Iron Core Reactor

K2.13 #8 Red 12" 2/K2 RC cans-3&5 Air core Reactor

K2.16 #8 Red Sized to Fit 2/K2 RC cans-0 Air core Reactor