ElectroFlowTM Installation Manual

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CREATIONOF VALUE

Electenergy Technologies, Inc. (ETI) is a leader in the energy products and

services industry, by challenging wisdom and creating superior values through
innovations. A company of high achievers, a company of ethical, energetic and
aggressive people who want to succeed . . . and do!

With this uncompromising dedication to excellence, we are consistently developing

and offering our unparalleled products and services to our customers throughout
the world.

Perfection is our Goal!

(Excellence will be tolerated.)

WARNING! This document is subject to copyright and is the property of Electenergy Technologies
Inc.; any duplication, reproduction, or photo static of any section of this Manual, either in whole or
in part without express written consent of Electenergy Technologies Inc. is prohibited, and can result
in legal action and cancellation of the Licensee’s/Consultant’s Agreement/Contract!
 Electenergy Technologies, Inc. (ETI)
ETI is a dynamic and aggressive national and international electrical/energy
engineering firm. ETI provides one-of-a-kind, state-of-the-art technology and
related products and services to its Licensees and customers. ETI is a privately held
and debt free corporation, with its World headquarters in Columbia, Missouri,
U.S.A. ETI is operating nationally as well as internationally, being represented on
six continents. ETI has a history of providing our customers with substantial
electric/energy savings through guaranteed performance of reliable products and
services to companies that are concerned with making their facilities performance
efficient and cost effective.

We offer highly advanced systems in the fields of electricity and energy.

Combining our vast experience with both theoretical and practical technical
knowledge allows us unique insight into electrical/energy use and conservation. Our
systems have delivered power savings as high as 34%, while protecting equipment
and machinery and reducing maintenance and downtime.

Our organization has a long history of service to industry, and we have developed a
flexible and compliant relationship with our customers, keeping their immediate
goals and needs uppermost in mind. Since inception, ETI has offered our customers
and Licensees free engineering consultation services in conjunction with our quality
products and installations.

Small and large customers, both nationally and internationally, have enjoyed the
benefits of ETI’s products and services. We have built our business and reputation
upon one satisfied customer or Licensee at a time. We believe in doing the job right,
in a timely and efficient manner, to the client’s complete satisfaction. We offer the
finest, most technically advanced design, fabrication, and equipment, as is
demonstrated in our ElectroFlow™ system. A power conditioning and energy
savings system.

If there is a better way to do it . . .

We will find it!

 Inspection, Installation and Startup

Inspection

A) Disclaimer
These instructions cover recommended practices for the inspection, installation and
maintenance of the ElectroFlowTM System. They do not address themselves to the
requirements of national and/or local codes, nor to the requirements of insurance
underwriters or the National Electrical Code, which might be applicable to any given
installation.

Compliance with codes and underwriters’ requirements demand individual consideration on

the part of the ElectroFlowTM System’s users for each particular situation. Compliance
should not be assumed to have been achieved simply by adherence to the suggestions
contained in this manual.

Upon receipt, make sure that there is no external damage to the box or enclosure. If
there is, you must mention that in the receipt from the carrier, and then file a damage
report with the carrier!

Note: ETI is not responsible for any damage(s) done to the cabinets, boxes, or
enclosures delivered to you by carrier, as every package and shipment goes through
stringent quality control and inspection prior to shipment. In addition, the carrier
accepts and signs a form that he has picked up the shipment in good condition and
without any damage(s).

B) General
Check the ElectroFlowTM System components to ensure that no damage has occurred
in transit. Vibration during shipment may cause the wire/cable, connections, and
inside components to loosen.

Check that the ElectroFlowTM System voltage, current, phase and frequency ratings are
appropriate for the electrical distribution supply to which it is to be connected. Before
installing, check all terminal connections for proper tightness.

Tighten RC cans’ terminal connections to 16 inch-lb. Tighten terminal block and fuse block
connections to 25 inch-lb. Tighten contactor terminals to the specified inch-lb. to ensure
optimum tightness, as they are most likely to loosen during shipment!
Note: The following monitoring devices, accessories and hardware are not
supplied by ETI, unless otherwise stated in writing (refer to the Purchase
Agreement/Contract), and therefore, remain the buyer’s/user’s
responsibility:
1) External monitoring C.T.’s (Current Transformer(s)).
2) External monitoring P.T.’s (Potential Transformer(s)).
3) ElectroFlowTM three-phase main power breaker(s)/disconnect(s).
4) ElectroFlowTM single-phase control voltage breaker(s)/disconnect(s).
5) Cables/wires connecting ElectroFlowTM to breaker(s)/disconnect(s).
6) Cables/wires connecting ElectroFlowTM to power source/load.
7) Conduits/Cable trays required for the above cables/wires.
8) Installation of electrical, mechanical and safety hardware, in general, as required by
national and local codes/laws.
 Installation of ElectroFlowTM System

Physical Mounting of System Components

1) Refer to installation drawings for specified placement sequence of
components. Select a mounting location such that the ElectroFlow
cabinet is less than 20 feet (cable length) from the ElectroFlowTM
power breaker/Disconnect switch.
Note: Make sure that the ElectroFlowTM three-phase power breaker is at least
20 feet away from the customer’s utility meter. If not, please
advise ETI at the same time as you are submitting your Link Analysis
through RAPS; as that will affect the ElectroFlowTM hybrid
configuration layout, and the performance verification!

2) Mount each cabinet with solid fasteners using good engineering practice
and in accordance with applicable national and local codes.

3) If mounted near a ceiling, maintain a minimum of 12 inches between top of

enclosure and the ceiling.

4) If mounted side-by-side, maintain at least 1 inch between enclosures.

Ambient Temperatures

High operating temperatures will reduce the life of the ElectroFlowTM System
components. Therefore the system should be located in an area of unrestricted
ventilation and mounted away from hot objects and surfaces. Never attach to (or
near) a heat source, or in direct sunlight.
Maximum safe ambient temperature is 120 F (50 C). If the temperature is below -
40 F (-40 C), before the ElectroFlowTM System is energized, internal damage to
the RC cans may occur when the system is turned on. To prevent this, the
components should be brought to at least +10 F (-12 C) before being energized. If
extremely low temperatures are expected, it is advisable to keep the RC cans
energized, in order to maintain their internal temperature above the critical point.

Connections
1) Follow the component sequence and cable routing as specified in the
installation drawings. DO NOT shortcut phase wire connections by tapping them
off of a more convenient point! It is essential that the ElectroFlow™ System must
be connected exactly as specified! (Refer to the installation diagram)

2) Electrical connection of components can be made by conduit or nipple

entry. Connect the wires to the designated terminal connectors. Incoming power
 connection to the ElectroFlowTM System breaker/disconnect shall be made with
proper size cable and in accordance with applicable national and local codes/laws.

3) The rating of the cables used to connect the ElectroFlowTM System is

based on the rated current of the ElectroFlowTM System. For cable, switching and
protective device sizing, please refer to the installation drawings for a particular
project. It is strongly recommended that prior to each installation, ElectroFlowTM
user(s) verify all installation related hardware sizes such as breaker/disconnect,
fuses, cables, conduits, etc., in accordance with applicable national and local
codes/laws.

4) DO NOT attach the ElectroFlowTM System to the load side of the motor
starter protective device on a reversing, plugging, jogging, inching or multispeed
motor! Serious damage may occur to the motor or the RC cans, if the ElectroFlow is
connected in this manner.

5) DO NOT use parts other than those supplied by ETI. Use of other
components will void warranty and may cause damage to ElectroFlowTM System
and other electrical equipment.

6) When installing the control C.T. (Current Transformer) for the

ElectroFlowTM Regulator, make sure you do not open-circuit the C.T. Connect the
C.T. to the Regulator, or short circuit the C.T. before installing the C.T. around buss
bars or cables.

Note: The control C.T. must be installed closest to the plant’s Main power breaker in
the main panel board, and on phase “A”. Please insure that the control
voltage wires for phase “B”, and “C” are connected close (within three feet)

to the phase “A” control C.T. When making control voltage connections to
phases “B” and “C”, make sure you properly protect them by using a
single-phase breaker/fuses.
INITIAL START-UP OF ElectroFlowTM SYSTEM
1) If ETI is responsible for the system startup, refer to the System sales Agreement. After the
installation is completed, leave the system OFF and contact Electenergy Technologies Inc.
An ETI trained field engineer will be dispatched to review the system installation. After a
check of all components, the ElectroFlowTM System will be commissioned and its full
capabilities demonstrated.
2) If ETI is not responsible for the system startup, refer to the System Sales Agreement and
your ElectroFlowTM supplier. Proceed with the start-up as instructed.
3) Check to insure proper size, installation and connection of the ElectroFlowTM main power
breaker/disconnect to the power supply as assigned.
4) Check to insure proper size, installation and connection of all three-phase cables to the
ElectroFlowTM main power breaker/disconnect are done in accordance with all national and
local codes/laws.
5) Check to insure proper routing of all three-phase cables are done in accordance with all
national and local codes/laws, whether in conduits, cable trays, duct or free-air.
6) Check to insure proper size, installation and connection of all three-phase cables to the
ElectroFlowTM internal terminal block(s) are done in accordance with all national and local
codes/laws.
7) If ElectroFlowTM is equipped with a Regulator, check to insure proper size, installation,
connection, routing and protection (breaker/disconnect and fuse size) of required Regulator’s
control wires per voltage and current are done in accordance with all national and local
codes/law.
8) With ElectroFlowTM’s breakers/disconnects “OFF”, using a V-O-M, set the meter selector
switch to Ohm and check to make sure no short circuit exists between any of the hot phases
(phases A, B and C), and neutral/ground, and the cabinet at each of the following locations:

a) Terminal Blocks
b) Fuse Blocks
c) Line side (supply side) of each inductor/reactor, whether iron core or air core
d) Load side of each stage contactor
e) Load side of breaker(s)/disconnect(s)

If you observe the slightest meter movements or readings, DO NOT turn ElectroFlowTM
“ON”. Proceed to locate the cause of the short circuit, repair/eliminate the problem, and
repeat the same series of tests.
9) With ElectroFlowTM breakers/disconnects “OFF”, using a V-O-M, set the meter selector
switch to Ohm. Proceed to take phase-to-phase readings (A to B, B to C and C to A) at the
following locations:

a) At the load side of each stage-contactor, if present

b) At each terminal block, if no stage-contactor is present

Note: Meter should display slight charging and discharging.

10) Close/replace ElectroFlowTM cabinet door(s).
11) If all measurements/tests satisfy the pre-startup requirements, then proceed to turn
ElectroFlowTM breaker(s)/disconnects(s) “ON”.
12) If you observe the slightest sparks, unexpected noises or overheating/burning odor, turn the
ElectroFlowTM “OFF”. Locate the problem, repair/replace parts or components as needed.
Repeat all pre-startup steps for measurement and tests.
13) Manually activate each stage of ElectroFlowTM using its Regulator, follow the instructions
given in the Regulator’s Operation Manual. If everything operates as expected, you
may then switch ElectroFlowTM Regulator to the automatic mode, and observe its operation.
(Refer to Operation Manual).

Quick Checkup

As a quick way to identify whether or not all ElectroFlow™ parts are working
properly, you should follow the 1, 2, 3 test:

1- When ElectroFlow™ is in operation, take Amp readings at each phase of

the ElectroFlow™ main breaker/disconnect switch. You should observe
that:

A- The Amp draw of each phase, at the ElectroFlow™

Main Breaker/Disconnect Switch matches the equivalent
KVAR of ElectroFlow™ as specified in the “Specification
Sheet”. You can find this value in the Technical Manual.
B- The Amp draw of each phase is equal to the other two
phases, and are equal to:

KVAR × 1000
I=
3 ×V

If both A and B above are satisfactory, ElectroFlow™ is operating

optimally. If not, proceed to “2” below.

2- If either A or B is not satisfactory, then you must observe that:

I- The Amp draw of each phase, at each stage of the

ElectroFlow™ at the supply side of the breaker of each
stage, matches the equivalent per-stage KVAR of
ElectroFlow™ as specified in the “Specification Sheet”.
You can find this amount in the “Typical Recommended
Ratings of Cables and Protective Devices” in the
Technical Manual. If you register no Amp readings, it is
likely that either the breaker or the contactor has
malfunctioned. Repair or replace the breaker/contactor as
needed.
 II - The Amp draw of each phase of each stage must be
equal to the other two phases for the same stage, and are
equal to:

KVAR × 1000
I=
3 ×V

If not, it is likely that one of the RC cans in that stage is

damaged, and it must be replaced!

If both I and II above can be rectified satisfactorily,

ElectroFlow™ will be operating optimally. If not, proceed
to “3” below.

3- If all tests and possible corrective measures taken at “1” and “2” above do
not rectify the problem(s), please turn ElectroFlow™ “Off”, then
contact ETI!
 ElectroFlow™ Troubleshooting Guide
Please follow all safety precautions, and use care to proceed with troubleshooting.

ElectroFlow™ Satellite Units

ElectroFlow™ Regulator-equipped system is referred to as K1 cabinets, and the ElectroFlow™

Satellite units are referred to as K2 and K3 cabinets.

General
Aside from specific problems relating to Regulator(s), Control Relays, and Controllers, which you
must refer to that section for further details. The following instructions are applicable to all units for
verification of proper operation:

1- Determine equivalent KVAR size of ElectroFlow™ from the nameplate.

2- Determine how many Amps the unit should be drawing, from the sizing-
table.

3- Using an Amp meter, measure the current draw of each phase, at load-side
of the ElectroFlow™ breaker/disconnect switch. Each phase must be
drawing the same amount of Amps, and should match the amount listed in
the sizing-table in the Technical Manual of ElectroFlow™, or use the
following formula:

KVAR × 1000
I=
3 ×V

4- If the Amp reading is not the same for all three phases, it is likely that a
failure may have occurred at one of the resistor/capacitor cans. To
determine an RC failure, you may:

A- Look on top of each can; if you see a bump or a bulge on top of an

RC can, that is the sign of failure, and must be replaced.

B- Measure the current draw of each phase of each RC can, you will
find that one does not match the rest. You may proceed to replace
the can.
CapTel 618
All of the ElectroFlowTM Satellite units (K2, and K3) are equipped with CapTel
618. There are three independent (for phases A, B & C) specially wound C.T.’s
with controls, which continuously monitor current and presence of voltage.

K3 Cabinet – Represents a single-stage ElectroFlowTM Satellite unit. In this

case, there will be three GREEN LED’s, representing (from left to right) phases
A, B, and C. If the LED’s are illuminated brightly, all of the three phases are
operating properly, and as designed. If however, one of the GREEN LED’s is dim
or not lit, that can be a sign of weakness/failure of a cell within the RC can of the
respective phase. You must check with an Amp meter to verify!

K2 Cabinet – Represents a two-stage ElectroFlowTM Satellite unit. In this

case, there will be three GREEN LED’s, representing (from left to right) phases
A, B, and C of the stage #1, and the three RED LED’s, representing (from top to
bottom) phases A, B, and C of the stage #2. If the RED LED’s are illuminated
brightly, all of the three phases are operating properly, and as designed. If all
three RED LED”s are “OFF”, check to make sure that stage #2 is “ON”(by
observing the contacts of the contactor). If however, one of the RED LED’s is
dim or not lit, that can be a sign of weakness/failure of a cell within the RC can of
the respective phase. You must check with an Amp meter to verify!
 Time-Delay Current Relay

Model CR-100

• Detects Under Current

• Adjustable Trip Delay
• Adjustable Amp Setting
• Auto voltage selector
Description
Model CR-100 Time-Delay Current Relay is designed to continuously monitor AC current.
CR-100 will detect under current conditions, and is adjustable from 0-5 Amps, with response
time of variable from .1 to 60 seconds. When Control Voltage is applied (110V-240V), a green
LED, labeled RLY, will light up. If the load current exceeds the current set-level, then the red
LED, labeled UL will illuminate.

Installation
Connect Control Voltage to CR-100 terminals: A1 and A2. The Control Voltage can be from
110V to 240V. Connect the first leg of the control voltage to the contactor coil-terminal A2.
Connect the second leg to the CR-100 terminal marked CC. Connect a wire from the CR-100
terminal marked NO to the contactor coil-terminal A1, as shown in the diagram.
Install External C.T., and connect its two wires to CR-100 terminals marked CT.

Control Voltage
(100V-240V)

To external CT A1 A2 Three-phase
LOAD Contactor 3-phase Supply
The above wiring connections are used when the supplied voltage to CR-100 is the same as the coil voltage of the
contactor.
ElectroFlow Regulator
Model 1333A

Application Manual

Electenergy Technologies Inc.

“Progress Through
Innovation”
P. O. Box 1291, Columbia, MO. 65205
Tel:(573) 814-1111, Fax:(573) 474-8888
Precaution

In order to assure your safety, the user should read this manual in full, before starting with the
installation. Make sure you properly connect all of the wires involving the ElectroFlow
Regulator Model 1333A, and in accordance with this Manual:

1. Model 1333A will not initiate any actions for 3 minutes after start, for the safety
considerations.

2. Power Supply - Check the system specifications and make sure the ratings for
each specification(s) are proper, including auxiliary power, voltage and current
connections.

3. Peripheral - The protective devices for the P.T., and C.T., must be in accordance
with the specification(s).

4. Maintenance and repair – For any repair or maintenance, you must

contact ETI for any specific instructions in that regard. If, however, it is necessary to
work inside the ElectroFlow cabinet. Place a warning sign on or around the
ElectroFlow cabinet. Then make sure power (including the power to the ElectroFlow
system, as well as to its control circuitry) have been disconnected. You must then wait
for 3 minutes, before opening the cabinet door.

5. CT Requirement - The output rating of CT must be 5A. If the wire length

from the C.T. to the Regulator is within 20 feet, you may use #12AWG twisted-pair
wires. Minimum burden requirement is 5VA. Make sure that the secondary side of CT
has been shorted, before connecting the regulator to the C.T. Failure to do so, will
produce an excessive voltage that can damage the C.T. and harm the installer.

6. RESET - In case of any strange behavior, or malfunction of the unit. You must
disconnect all of the stages and the alarm, by resetting the unit. You must press

key, and then press key, simultaneously for 8 seconds; in order to completely rest
the unit. If after the above you still observe certain abnormality, or get abnormal data
from the display. You must disconnect the regulator, turn off the power supply to the
regulator and ElectroFlow system, and contact ETI for further instructions.

7. WARNING - You must not disassemble, tamper with, or try to access the
regulator’s internal circuitry, or remove its protective box for any reason. If the unit is
found to have been tampered with, opened, the box removed, or any such disassembly
taken place; ETI accepts no responsibility for any subsequent damage to the electrical
distribution or any harm to the operator or any humans affected by the same, and
considers the warranty VOID!
Introduction

ElectroFlow Regulator Model 1333A detects power factor value, as well as

Total harmonics Distortions (THD) of the power system, calculates effective KVAR value, and then
selects the appropriate stage to be connected or disconnected. The design of this unit took in
consideration the fast regulation objective, while protecting stage components.

Front Panel
Rear Panel

IMPORTANT
1. The transformer shown is external, and must be protected by line fuses.
2. BL, and CL represent primary side of the transformer, where Bx, and Cx represent secondary
side of the transformer. Both sides must be protected by fuses.
3. Input to the voltmeter can be 0-510 V. Voltage in excess of 510 V MUST NOT BE
APPLIED, where serious damage to equipment and personnel will result!!!
Specifications

Electrical

Supply power: ElectroFlow Regulator Model 1333A can accept four different
ranges of voltage.

Voltage Range (±15%)

110 V 94 ~ 126 V
220 V 187 ~ 253 V
380 V 323 ~ 437 V
480 V 374 ~ 506 V

Consumption: 10 VA maximum
Frequency: 45 ~ 65 Hz.
Current sensing: 0.1 ~ 5 A
Output: Six stages
Alarm contact: Al1 and Al2 (normal open) contact, each high/low limit can be
set separately
Relay Ratings: AC 250 V, 5A (resister loading)
Relay Life period: 50,000,000 times
Operating Temp.: 0 ~ 50 °C (32 ~ 122 °F)
Storage Temp.: -10 ~ 70 °C (14 ~ 158 °F)
Humidity: 0 ~ 90 %
Display function
Display item Range Accuracy

Power factor 0.00 ~ 1.00 (Lag/Lead) ±0.02

Voltage 0 ~ 510 V (THD mark) ±0.5 %

Current 0 ~ 6000 A (THD mark) ±0.5 %

KVAR 0 ~ 9999 KVAR ±2 %

Frequency 40 ~ 70 Hz ±0.1 Hz
Temperature 0 ~ 70 OC ±3 OC

Dimensions
Panel size: 144 X 144 (mm)
Panel cut out size: 138 X 138 (mm)
Depth: 105.4 (mm) includes terminals
Functions Description

Settings Status
A total of 8 items can be set in Settings Status; their functions are as follows:

1. PF setting - When a desired True PF value is set, Model 1333A will start
activation in consideration of each stage values and the effective KVAR values, until it
meets or exceeds the desired power factor.
2. P.T. setting - If an external P.T. is used, input its ratio. For example, if the P.T. rating is
2000V:200V, the ratio setting would be 10.
3. C.T. setting - When you use an eternal C.T., input its ratio. For example, if the C.T.
rating is 2000A:5A, the ratio setting would be 400.

4. Delay time - Model 1333A activates stages based on a time-delay function. If you
decrease the time delay, the unit responds faster, and vice versa.
5. RC cans discharging protection - Proper time-delay should be set for the stages
for their activation and inactivation. If a short time-delay is selected, the connection,
disconnection of stages will be more frequent, and the response will be faster. It is important
to note that the time-delay selected must be greater than the time required for the discharge
of each RC can in the circuit.
6. Phase - Refer to Phase Mode and wiring diagrams, to correctly set number of phases, i.e.
1, 3, or 4.
7. Alarm delay-time - If the delay time selected on the display panel deviates from the
alarm setting value, the alarm will be activated after the "Alarm delay time".
8. Light-duty inactive limit - In order to prevent leading power factor, protective logic
has been integrated intoModel 1333A; the setting range is 0%-20% based on the
maximum power (KW). Once Model 1333A detects KW value lower than light-duty,
it enters into low-power mode; at this time, Model 1333A will disconnect the
appropriate stage(s) based on any excess voltage, power factor, or THD accordingly. This
status will be maintained until such time that KW value rises and is larger than light-duty
inactive limit, Model 1333A will then reset to its normal automatic operation status.
Stage-cycling principal
Model 1333A connects and disconnects stages based on the preset configured values. If,
however, the key factors remain within the normal window of response, it follows the equal-use
principle by first-in and first-out connection / disconnection of the same capacity, in order to prolong
the life of contactors as well as the components. However, if the load conditions and behavior does
not remain within the same window, Model 1333A will react accordingly and active the
stage(s) as required.

High/Low limit alarm-output

Once one of the six values of alarm settings displayed on the panel, is opened, and the value is still
higher than the set high-limit or lower than the set low- limit, after exceeding the set alarm delay-
time, alarm indicator and the item indicator will flash quickly, meanwhile, the alarm contact will be
closed.
Installation

Voltage connections

Auxiliary power
Model 1333A can use power in four different ranges, each 110, 220, 380 and 480VAC. There
is no protective fuse used inside Model 1333A. As a result, either a 3Amp fuse or breaker
must be used in-line with the supply voltage of the Model 1333A.

Voltage meter input

(510 V MAX)
Current connections
Model 1333A current input connects to secondary of a C.T. output. Model 1333A can
detect 0.1 ~ 5 Ampere.
Note: If you intend to use an existing C.T. from the customer’s panel Current Meter, you must insure
that the connections are made in accordance to the following:
Wire Connection Diagrams

Three-phase Three-wire system

If you would like to connect the Model 1333A to a three-phase three-wire system, you must
connect the external C.T. to phase A, and the two phase-voltages to phase B and phase C. You
must insure that:

• The C.T. and the two voltage connections (phase B, and phase C) be made immediately after
the customer’s Main service breaker.
• The C.T. and the two voltage connections (phase B, and phase C) be made close to one
another, and at the same spot.
• The length of the four control wires (two wires for the C.T., and two wires for the voltages)
be less than 20 feet, where you may use #12 AWG wires. If the lineal length (wire length) is
greater than 20 feet, please refer to the table in the Technical Manual.
Three-phase Four-wire system

You may connect the control wires in a Three-phase Four-wire system, in accordance
with the following diagram. Make sure that you set "4" in "Phase Setting " of the Model
1333A display panel.

Single-phase System

You may even connect the control wires in accordance with the following diagram.
Settings
All of the settings, as stored, can be preserved for at least two months after power failure, and if
power is not applied to the unit in the interim.
You must enter your settings in 5 minutes! If you spend more than 5 minutes to enter the settings,
Model 1333A will switch into the protective mode, as it assumes that an authorized person is
trying to change the settings. This protection can be turned off until the next “RUN” mode, so you
may make the appropriate changes. For further information to enter the relevant information for the
“IN”, and “OUT” status, please refer to the ”Setting protection mode”, as well as "Release setting
protection Mode".

Release Setting protection mode

Press key, and key simultaneously, for 8 seconds. If the display shows "PAS". This will
permit entering into setting status for 5 minutes again if you had waited too long to enter settings
after power up.

The settings will be protected from an unauthorized person by automatically entering into “Setting-
protection mode” 5 minutes after the unit powers up. If it is necessary to change any settings after
this time period is over, you must follow the above instructions.

Important: The “Setting-protection mode” will always reactivate after the unit has been in a normal
mode without going into the Settings Mode for 5 continuous minutes.
Function setting

With regard to the functions and their respective setting ranges, please refer to Table 1 in this
section. The setting procedures are described below:

1. Press key, and press key for 2 seconds simultaneously. At this time, one of the
item indicators will flash slowly—showing that Model 1333A is in Setting Status.

2. Press key, or press key to decrease or increase the setting value.

3. Press to cycle to the next function to set—The related item indicator will flash slowly.

4. Repeat steps 2 & 3 above as needed.

5. Press key to return to Automatic Operation status.

Table 1 The items of settings status

Item on panel Name of the setting item Setting range Preset value
COS θ PF value 0.8 Lag ~ 0.9 Lead 0.98 Lag
V PT ratio 1 ~ 800 1
A CT ratio 1 ~ 1200 1
KVAR Delay time 2 ~ 600 (sec) 240 (sec)
HZ RC cans protection-time 10 ~ 255 (sec) 180 (sec)
TEMP Phase type 1, 3, or 4 3
ALARM Alarm delay-time 0 ~ 999 (sec) 0 (sec)
MAN Light-duty inactive limit 0 ~ 20 % 1%
Stage Settings And SDF

Model 1333A allows each stage to be set with different values, based on the reactive
compensation (KVAR). Using this technique, the Self Diagnostic Feature (SDF) cannot only identify
the appropriate correction based on the load requirement, but it can identify whether there is any
component failure on per-phase, and per-stage basis, isolating the malfunctioned part/component-
stage, so that no imbalance of compensation, and subsequent asymmetrical components will result.
The per-stage setting of reactive compensation can vary from 0 to 1800 (KVAR). Please set "0" in a
stage, if that stage does not use any reactive compensation. Even if all stages are set to “0” (i.e. the
initial reactive compensation of each stage is "0"), Model 1333A can still operate
automatically.

Important note: The settings for each stage are cumulative, including the compensation applied by
the previous stages. Stages with no reactive compensation still remain “0”. For example, if each
stage has the following amounts of reactive compensation, each stage respectively 1 through 6
(KVAR): 50, 50, 50, 25, 25, and 0, the settings for each stage would be as follows: 50, 100, 150, 175,
200, and 0. If a stage has a non-integer value of reactive compensation (i.e. 12.5 KVAR), round to
the nearest integer (i.e. 13 KVAR).

Following are the operation settings, under the Automatic Operation status:

1. Press key, and press key for 2 seconds simultaneously, at this time, the stage
indicator and display will flash slowly, and show setting status is entered.

2. Press key, or press key to decrease or increase the reactive compensation of that
stage in KVAR.

3. Press key to set the next stage reactive compensation in KVAR.

4. Press key to return to Automatic Operation status.

Alarm setting status
All of six functions displayed on Model 1333A panel can be set at high limit and low limit to
open/close alarm function separately, as follows:
Alarm setting item High limit setting Low limit setting

COS θ (Power Factor) { 

V (Voltage) { 
A (Ampere) { 
KVAR (Kilo VAR) { 
HZ (Power Frequency) { 
TEMP (Temperature) { 
If the alarm is turned on for a function, the alarm will activate after the delay time if the current status of that
function is beyond the entered limits. For example, if the temperature alarm is turned on and the lower and
upper limits are 5OC and 50OC respectively, and the alarm delay was set at 60 sec, the moment that the
temperature has been either below 5OC or above 50 OC continuously for at least 60 sec, the alarm will activate.
Under Automatic Operation,

1. Press key to select the item for which you wish to activate the alarm.

2. If high limit alarm is to be entered, press key for 2 seconds; If low limit alarm is to be

entered, press key for 2 seconds, at this time, display and the indicator will flash
slowly, it shows setting status is entered.

3. Press key once to open (display is showing value) or close (display is showing OFF)
high limit alarm or low limit alarm of the item.

4. Under alarm function status is open, press key or press key to decrease or
increase the alarm setting value.

5. Press key to return to Automatic Operation status.

System Reset
The operation procedures for resetting the initial set values of Model 1333A under
Automatic or Manual operation are as follows:
Press key, and press key for 8 seconds, at this time, if Model 1333A entered into
self-testing status, the reset is finished.

Function operation

Check information
Under Automatic or Manual operation status, press key to check each parameter
information on panel respectively.

Display item Range

PF 0.00 ~ 1.00 (Lag/Lead)
V 0 ~ 510 V
A 0 ~ 6000 A
KVAR 0 ~ 9999 KVAR
HZ 40 ~ 70 Hz
TEMP 0 ~ 70 OC
Manual Status
Under Automatic Operation status,

1. Press key for 2 seconds, then item indicator "MAN" will flash slowly; it shows
manual operation status is entered.

2. Press key or press key, stages will be activated or disconnected; if it indicates

"Er.1", it means repeat operation has to wait after a while or the stages are all inserted or
disconnected and the minimum delay time has not expired.

3. Press key to return to Automatic Operation status.

Quick Power Factor Check
If you wish to have a quick check of the power factor setting, under Automatic or Manual
operation status, you proceed as follows:
1. Simultaneously press and key.

2. At this time, power factor set value(s) will be displayed. Release two keys simultaneously, if
you are finished with the quick check.
Troubleshooting
Error Display Possible Reason Remedy

Insertion Error 1. Wait until the stage discharging protection time is

Er.1 passed, then insert again.
(Operation error) 2. No Capacitor can be inserted.
Disconnect error No stage can be disconnected
Phase-order error Please identify phase-order again
Er.2 Phase-setting error Identify single phase or three-phase status, and then
(Phase error) enter function-setting status to check phase type setting.
(TEMP item)
CT connect error Exchange voltage (P0 and P1.P4), or Current (K and L)
connection
Input current too high Must review the load current, and the connections to
Er.4 find the problem.
(Over current) CT ratio too small Must replace C.T with a larger ratio one.
Load is too small Wait until the load reaches normal operation.
Lo.
(Low Power)
Reference

Wiring diagram
The wiring diagram is as shown below:
 Power RC Cans
The ETI RC Cans are built to NEMA industrial grade standards for long life at the work
site. The assemblies are specifically designed in a tank formation for the customer’s
electrical load from the power measurements taken during plant operation and analysis of
load performance. Individual cells are built into a stage, which is installed according to
ETI’s link analysis.

The stage(s) may include automatic switching if necessary. Some stages are equipped
with arc retaining, fast acting, and current-limiting protection. Their prime purpose is to
prevent cell rupture from short circuits, a hazard for cells of every type. A secondary
purpose is to take the shorted device off the line. Under certain operating conditions,
transients or odd harmonic currents can cause the breaker/fuses to blow, even though
individual cells may be unaffected.

Power Inductor/Reactor
The ETI iron-core reactors are Variable Nonsaturable Zigzag type, which are built to
NEMA industrial grade standards, and match at least NEC’s standard requirements.
Specific characteristics and ratings of each unit is based on data and measurements
contained in the Link Analysis. Refer to each system’s Specification Sheet for further
details.
 MAINTENANCE OF ElectroFlowTM SYSTEM

A. General
1) After initial startup, no further maintenance should be necessary during life of the
ElectroFlowTM System under normal service conditions.

2) DO NOT disconnect and reconnect the system without advising ETI, as incorrect
reconnection may cause damage to the system and operate incorrectly.

3) WARNING: Power must be switched “OFF”, and the ElectroFlowTM

System must be
completely electrically isolated, before doing any work on or inside the
system. To ensure that the system has been disconnected from the power source,
make a visual check for an open contact at the ElectroFlowTM System
breaker/disconnect and carry out a voltage check on the input terminals of the
ElectroFlowTM System. With ElectroFlowTM Systems, which include staged
switching, using an ElectroFlowTM Regulator, make sure both of the breakers: The
three-phase power breaker, and the single-phase control breaker are switched
“OFF”!
4) Note: Once power is “OFF”, High Voltage will still exist in the RC
cans. The discharge resistors in each RC can should drop the residual voltage to 50
volts or less, within one minute. However, you must short and ground the RC
cans, and the unit, before proceeding with any work.

5) Individual components should be inspected periodically to confirm their

operating status. After de-energizing, an RC can, resistor, inductor or reactor can be
easily checked by taking voltage readings. Or, take an Ammeter reading at the
nearest point available, such as the control cabinet. By touching a temperature
probe to the ElectroFlowTM enclosure you may determine the same. An operating
component will be warm, but not hot!

6) DO NOT leave the ElectroFlowTM System “OFF” for more than a few
minutes at times of high loads, as this may result in exceeding the monthly
Maximum Demand. This will result in a higher electricity Demand charge and
electric bill. It is, therefore recommended that maintenance be carried out at times
of low load.
B) Routine Maintenance Check-List
1) Check that ElectroFlowTM System three-phase display counter for operation status.

2) Check the SDF (Self Diagnostic Feature) status.

3) Check for visual indication of a hot component or connection within system.

4) Check for dust build-up on internal components. If dust build-up is evident, switch
“OFF” ElectroFlowTM System, then clean and vacuum.

5) See that ventilation pathways are clear of obstruction, particularly on both sides of
the ElectroFlowTM System enclosures. Clean any dust or fluff build-up.

6) If a part/component fails, contact ETI for the respective repair or replacement.

7) To check the RC cans, take a current reading of the cables supplying each
stage, when ElectroFlowTM System is in operation. EXERCISE UTMOST
CAUTION and follow all national and local electrical testing and measurement
codes. Each phase should have approximately the same current, in addition to
verifying the correct ampere drawn by referring to the Installation or Technical
Manuals.

8) If the ElectroFlowTM System is equipped with a Regulator, please refer to the

particular Regulator section for the specific instructions.
.

FAILURE TO CARRY OUT THESE PROCEDURES WILL VOID THE WARRANTY.

IMPORTANT NOTE:

In the case of any failure, malfunctions, or abnormal behavior, either directly or indirectly
related to the ElectroFlowTM System or associated equipment, TURN “OFF” the
ElectroFlowTM System immediately, and call your ElectroFlowTM supplier, or ETI at (573)
814-1111.

Any changes or modifications to the ElectroFlowTM System circuit

or components, not approved by ETI, shall void its warranty and
may cause damage to the system and other electrical equipment.
 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-KVAR per Phase (A) Cable @ 75°C Cable @ 90°C (Time Delay) Switch (A) Size (A)
240 Volt 240 Volt 240 Volt 240 Volt 240 Volt 240 Volt 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 800 800 450
250 601 (3)-300kcmil (2)-500kcmil 1000 1000 900
300 722 (3)-400kcmil (3)-350kcmil 1200 1200 1100
380 VOLTS
Capacitor Rated Current Min. Copper Min. Copper Fuse Amps Disconnect MCCB Size
3φ-KVAR per Phase (A) Cable @ 75°C Cable @ 90°C (Time Delay) Switch (A) (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
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!
415 VOLTS
Capacitor 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)
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 480 Volt 480 Volt 480 Volt 480 Volt 480 Volt 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
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!

600 Volts
Capacitor 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)
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
 Cable Specification/Conversion Table

CONDUCTOR
SIZE cmil mm2 STRANDING CONDUCTOR
DIAMETER
COPPER
CURRENT
area area IN INCHES 90C
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

 Performance Verification

It is very important to establish a base for actual conditions, and parameters

to be tested. Hence, the following facts should be used as guidelines for
accurately verifying performance of any energy saving devices, including
ElectroFlowTM:

Rule # 1: That ElectroFlowTM is a passive system, and does not

consume measurable real power (KW). This can easily be verified by actual
measurements taken at ElectroFlowTM main breaker/disconnect switch.

Rule # 2: That so called "energy saving devices that connect in series"

either alter normal load performance by interference, or adversely affecting
system power quality; or both! As a result, their performance must be
verified based on:

A. Load output/performance interference; such as: reduced motor speed,

reduced light lumens, and so on.
B. Power quality interference; such as: reduced voltage, generated
harmonics, increased distortion, and so on.
C. Fail-safe operation; since they connect in series, how trouble-free and
responsive their bypass mechanism functions!

Rule # 3: ElectroFlowTM connects in parallel. As a result, it is

guaranteed that the system is fail-safe. As concluded in Rule # 1 above, it is
passive and does not consume measurable real power (KW). Hence, for the
purpose of scientific evaluation, and the so-called “Apples-To-Apples”
comparison of ElectroFlowTM “ON”, and ElectroFlowTM “OFF”
conditions. It is required to tabulate all of the pertinent dependent variables:
Demand (KWD), and Usage (KWH), as well as all the independent
variables: Hours Of Operation, Percentage Of Operation, Units Of
Production, and Degree Hours.
Verification Method

1. Testing and measurements must be conducted using a three-phase

power analyzer capable of data logging at a minimum rate of 128 samples
per cycle, which equates to 7,680 times per second at 60 Hz, or 6,400
samples per second at 50 Hz. The three-phase variables to be measured, for
the purpose of power quality, as well as energy savings, are: voltage,
current, power factor, harmonics, Demand (KW), and Usage (KWH).

2. All of the three-phase values must be displayed per-minute, for

several consecutive periods of 15 minutes "ON" and 15 minutes "OFF", in a
spreadsheet format. This is practically recommended, because most of utility
companies' Demand meters register Maximum monthly KW Demand, based
on the highest sliding 15-minute interval in that month; which is
subsequently billed to and paid by the customer. In addition, such short-
duration sampling and comparison, minimizes effects of other independent
variables such as: load variation/load profile and change of weather, in such
comparison testing.

3. The collected data such as Demand (KW), and/or Usage (KWH)

should not be simply averaged, added, or subtracted; as means to analyze the
variables. Because it does not take load variation/load profile, and LOAD
FACTOR (Load Factor=(KWH x 100)/(KW x Hours)) into account. Such
incorrect method completely ignores the “Apples-To-Apples” comparison of
the data, as well as other pertinent variables.

In order to correctly analyze effects of the "ON" and "OFF" conditions on

Demand (KW), and/or Usage(KWH). Ideally, all of the independent
variables such as: Hours Of Operation, Percentage Of Operation, Units Of
Production, and Degree Hours should be kept constant. You may then
proceed to analyze Maximum Demand reduction from the test data of both
conditions, where Usage (KWH) reduction can be calculated from the
cumulative values of both conditions.

In the case of Harmonitor sampling rate at 256 samples per cycle, at 60 HZ

frequency, it samples 15,360 times per second. Hence, the per-minute
samples will be 921,600. Subsequently, since the demand period is the
integration of the area under the curve for that period, and it is designated as
15 minutes. The total samples for that period will be 13,824,000.
Furthermore, total number of samples per hour, in order to determine the
exact energy consumption based on the average value of every minute will
be 55,296,000.

In order to accurately analyze data, for energy consumption Usage, the

effects of the samples are cumulative, and based on the per-minute values.

This means all of the samples of 921,600 will be cumulatively averaged and
added to provide a number that represents the actual usage for that minute.

Subsequently, the demand interval is calculated based on the same principal,

but for the fifteen-minute integration of those values under the curve.

Since the load factor calculation is: Load Factor=(Kwh x 100)/(KwD x

Hours of operation). The actual number of samples calculated for one-
minute intervals, then the operating period will be determined based on one
minute.

In addition, since the energy consumption is based on the Kwh, which it

simply means Kw times the time. Hence, each per-minute sample of the
consumption will have to be cumulatively added to accurately sum the
energy usage in one hour. For that purpose, because the selected period of
the test is based on the fifteen minutes "ON" and fifteen minutes "OFF",
comprises of one set of the test. It is understood that the load is variable,
even on the per-minute basis, which for the sake of “Apples-To-Apples”
comparison load factor values of per-minute basis need to be calculated and
plotted with respect to time and order of the samples taken. Subsequently,
the 98% confidence level for linear/non-linear regression analysis needs to
be applied for both conditions for accuracy. Following that, the area between
the two lines will be the area of the energy consumption savings for that
period. This means, where ever the scatter points on the graph are positioned
outside of the 98% range, those points will be replaced by the mean average
values, which better represent the steady state running-load conditions, and
not a sudden change such as the inrush current or starting torque magnitudes.
Similarly, the effects on the demand can be determined using the same
methodology.
If the annual load profile of the facility is assumed to be the same as that of
the monitored period for the same month. The annual projected savings will
then be calculated based on the facility's load profile for a year. Similar
analysis may be performed in order to accurately calculate the demand
verification as well.

In an event, if one or more of the independent variables such as: Hours Of

Operation, Percentage Of Operation, Units Of Production, and Degree
Hours may not be kept constant; as dictated by the load. The most accurate
method is the correct use of a spreadsheet software, or a statistical software
such as Statistical Path Analysis (SPA), SPSS, or SAS. Use of one of these
software allows accurate comparison of Demand (KW), and/or Usage
(KWH) with respect to the above mentioned independent variables; using
linear/non-linear regression method. This facilitates pro-rated analyses of
the load variation/load profile based on the per-minute load factor, to
accurately determine demand and/or energy savings; even when the load is
fluctuating in a rapidly variable load profile. Such data is then compared
with the base load profile previously measured and documented. For this
purpose, the SPA software is commonly used to evaluate ElectroFlowTM
saving effects.

Contrary to the popular belief,

we cannot walk on water; YET.

But, we are working on it!