Soft Starter Handbook

SOFTSTARTER
HANDBOOK
FOREWORD
This book is written with the thought of being a general guide for people working with
softstarter applications but also for those just interested in learning more about this type
of starting method. It doesn’t matter if you are an expert or novice, hopefully you will find
some interesting and useful information either by reading from cover to cover or just the
chapters of interest.
The index at the end of the book can be used to simplify your search.
The content of this book is very much based on the 20 years of experience we have within
ABB of developing, manufacturing and selling low voltage softstarters.
The book is not a complete technical guide or manual for all type of ABB Softstarters that
may exist on the market. It is a complement to the technical catalogues and brochures we
have for our products and will give a general picture of what to think about when working
with softstarters.
More information about softstarters as well as other ABB products is available on www.abb.com
All advice given in this book is only general and every single application must be handled
as a specific case.
ABB Automation Technology Products AB, Control

February 2003
Magnus Kjellberg Sören Kling

ABB will not take any responsibility for any type of faults or damage due to the use of this
handbook.
Contents
Contents
Standards ...1
European Directives ...1
CE Marking ...1
Specification in USA and Canada ...1
Used standards ...1
General about motors ...2

Squirrel cage motors ...3
Voltage ...4
Power factor ...5
Speed ...6
Torque ...7
Slip-ring motors ...7
Different starting methods ...8

Direct-on-line start (D.O.L) ...9
Star-delta start ...10
Frequency converter ...12 I
Softstarter ...13
Common problem when starting and stopping motors ...14
Different applications ...15

Centrifugal fan ...16
Softstarter ...17
Selection of a suitable Softstarter ...18
Centrifugal pump ...19
Softstarter ...21
Compressor ...23
Contents

Softstarter ...25
Conveyor belt ...27
Softstarter ...29
How to select a softstarter ...31

Description of the softstarters ...33
Description of different components ...34
Common settings ...36
II Start ramp ...36
Stop ramp ...36
Initial voltage ...36
Current limit ...37
Step down voltage ...38
Adjustable rated motor current ...38
Different indications ...39
Different voltage names ...40

Ambient temperature ...41
High altitudes ...42
Start of several motors ...43
Parallel start of motors ...43
Sequential start of motors ...44
Contents
Different ways of connecting the softstarter ...45
In-Line connection ...46
Inside Delta connection ...46
Location of the main contactor ...47
Basic settings ...49

Table for settings without current limit function ...50
Table for settings with current limit function ...51
Starting capacity and overload protection ...52

Starting capacity for softstarters ...52
Starting capacity when using by-pass contactor ...53
Starting capacity when using overload protection ...53
Number of starts/hour ...54

Intermittance factor ...54
Harmonics ...55 III

Harmonic content ...55
Explosive atmospheres (EEx) ...56

Hazardous areas and zones ...57
Location and selection of softstarter ...57
Co-ordination ...58
Types of co-ordination ...59
Utilization Categories ...60
Types of fuses ...61
Where to find the co-ordination tables ...62
How to read the co-ordination tables ...63
ESD aspects ...65

Two type of faults and different circuits ...65
Electro static voltage levels ...66
Protection against ESD damages ...66
Frequently Asked Questions (FAQ) ...67
Contents
Environmental information ...69

LCA ...69
EPD ...70
Industrial IT ...71
Different levels ...72
Softstarter level ...72
Formulas and conversion factors ...73

Formulas ...73
Quantities and units ...75
Conversion factors ...76
Glossary ...78
IV Index ...84
Standards
Standards
All ABB low voltage softstarters are developed and manufactured according to the rules
set out in the IEC (International Electrotechnical Commission) which is a part of the
International Standard Organisation, ISO.
ISO issue IEC publications that act as a basis for the world market.
Softstarters built according to these standards are in most countries not subject to
any other tests besides the manufacturer responsibility. In some countries, law requires
certificates.
For softstarters used on board ships, maritime insurance companies sometimes require
certificates of approval from BV (Bureau Veritas), GL (Germanisher Lloyd) and LRS
(Lloyd’s Register of Shipping) or other independent certification organisation.
European Directives Specifications in USA and

There are three essential European directives: Canada
Low Voltage Directive 73/23/EEC The specifications for the American and
Concerns electrical equipment from 50 to Canadian markets are quite equal but differ a
1000 V AC and from 75 to 1500 V DC. lot from the IEC standards and other European
Machines Directive 89/392/EEC specifications. 1
Concerns safety specifications of machines USA UL Underwriters Laboratories
and equipment on complete machines. File ref. 072301-E161428
Electromagnetic Compatibility Directive 110800-E161428
89/336/EEC Canada CSA Canadian Standards
Concerns all devices able to create electro- File ref. 1031179
magnetic disturbance including the level of
emission and immunity. Used standards
Following standards are used or partly used for
CE Marking the softstarters.
When a product is verified according to its IEC 60947-1
applicable EN standard (EN 60947-4-2 for IEC 60947-4-2
softstarters) the product will then fulfil both the EN 60947-1
”Low Voltage Directive” and ”Electromagnetic EN 60947-4-2
Compability Directive” and it is allowed to use UL 508
the CE marking on the product. In this case CSA C22.2 No. 14 - M91
the CE marking does not cover the ”Machines LRS 00/00154
Directive” concerning the connection of the
softstarter for a safe run of the motor.
The CE marking is not a quality label; it is proof
of conformity with the European Directives
concerning the product.
About Motors
Modern electrical motors are available in many different forms, such as single phase
About Motors
motors, three-phase motors, brake motors, synchronous motors, asynchronous motors,

special customised motors, two speed motors, three speed motors, and so on, all with
their own performance and characteristics.
For each type of motor there are many different mounting arrangements, for example
foot mounting, flange mounting or combined foot and flange mounting. The cooling
method can also differ very much, from the simplest motor with free self-circulation of
air to a more complex motor with totally enclosed air-water cooling with an interchangeable
cassette type of cooler.
To ensure a long lifetime for the motor it is important to keep it with the correct
degree of protection when under heavy-duty conditions in a servere environment.
The two letters IP (International Protection) state the degree of protection followed
by two digits, the first of which indicates the degree of protection against contact
and penetration of solid objects, whereas the second states the motor’s degree of
protection against water.
The end of the motor is defined in the IEC-standard as follows:
• The D-end is normally the drive end of the motor.
2 • The N-end is normally the non-drive end of the motor.
Note that in this handbook we will focus on asynchronous motors only.
Terminal box
Cooling fan
Drive shaft
D-end N-end
Stator windings Stator

Rotor
About Motors
Squirrel cage motors There are also other parameters that differ.
The design of the rotor affects the starting current
In this book the focus has been placed on the and torque and the variation can be really large
squirrel cage motor, the most common type of between different manufacturers for the same
motor on the market. It is relatively cheap and power rating. When using a softstarter it is
the maintenance cost is normally low. There are good if the motor has a high starting torque at
many different manufacturers represented on the Direct-on-line (D.O.L) start. When these motors
market, selling at various prices. Not all motors are used together with a softstarter it is possible to
have the same performance and quality as for reduce the starting current further when compared
example motors from ABB. High efficiency to motors with low starting torque. The number
enables significant savings in energy costs during of poles also affects the technical data. A motor
the motor’s normal endurance. The low level of with two poles often has a lower starting torque
noise is something else that is of interest today, than motors with four or more poles.
as is the ability to withstand severe environments.
I Max. starting current Max. torque

T
Starting torque
Rated current Rated torque
rpm rpm
Current diagram for typical sqirrel cage motor Torque diagram for a typical squirrel cage motor
Voltage The winding is delta connected at 230 V and if
About Motors
the main voltage is 400 V, the Y-connection is

Three-phase single speed motors can normally used.
be connected for two different voltage levels.
The three stator windings are connected in star When changing the main voltage it is important
(Y) or delta (D). to remember that for the same power rating the
rated motor current will change depending on the
The windings can also be connected in series or voltage level.
parallel, Y or YY for instance. If the rating plate
on a squirrel cage motor indicates voltages for The method for connecting the motor to the
both the star and delta connection, it is possible terminal blocks for star or delta connection is
to use the motor for both 230 V, and 400 V as an shown in the picture below.
example.
L1 L1
W2 U1 U1
U2
W1 U2 V2
4 W2
L3 L2 V1
V2 V1 L3 W1 L2
W2 U2 V2 W2 U2 V2
U1 V1 W1 U1 V1 W1
L1 L2 L3 L1 L2 L3
– Connection Y – Connection
230 V 400 V
(400 V) (690 V)
Wiring diagram for Y- and Delta connection
About Motors
Power factor The ratio between the active power (kW) and the
reactive power (kVA) is known as the power
A motor always consumes active power, which it factor, and is often designated as the cos ϕ. A
converts into mechanical action. Reactive power normal value is between 0.7 and 0.9, when
is also required for the magnetisation of the motor running where the lower value is for small motors
but it doesn’t perform any action. In the diagram and the higher for large ones.
below the active and reactive power is represented
by P and Q, which together give the power S.
P S
Diagram indicating P, Q, S and Cos ϕ

Speed The difference between the synchronous and
About Motors
asynchronous speed also named rated speed is

The speed of an AC motor depends on two things: ”the slip” and it is possible to calculate this by
the number of poles of the stator winding and using the following formula:
the main frequency. At 50 Hz, a motor will run
n -n
at a speed related to a constant of 6000 divided s= 1
n1
by the number of poles and for a 60 Hz motor
the constant is 7200 rpm. s = slip (a normal value is between 1 and 3 %)
To calculate the speed of a motor, the following n1 = synchronous speed
formula can be used: n = asynchronous speed (rated speed)
n = 2 x f x 60 Table for synchronous speed at different
p number of poles and frequency:
n = speed
f = net frequency No. of poles 50 Hz 60 Hz
p = number of poles
2 3000 3600
Example:
4-pole motor running at 50 Hz 4 1500 1800
n = 2 x 50 x 60 = 1500 rpm 6 1000 1200

4
6 This speed is the synchronous speed and a
8 750 900
squirrel-cage or a slip-ring motor can never 10 600 720
reach it. At unloaded condition the speed will
12 500 600
be very close to synchronous speed and will
then drop when the motor is loaded. 16 375 450
20 300 360
Rated speed
Syncronous
speed
}
Slip rpm
Diagram showing syncronous speed vs.rated speed
About Motors
Torque Slip-ring motors
The starting torque for a motor differs significantly In some cases when a D.O.L start is not permitted
depending on the size of the motor. A small due to the high starting current, or when starting
motor, e.g. ≤ 30 kW, normally has a value of with a star-delta starter will give too low starting
between 2.5 and 3 times the rated torque, and torque, a slip-ring motor is used. The motor is
for a medium size motor, say up to 250 kW, a started by changing the rotor resistance and when
typical value is between 2 to 2.5 times the rated speeding up the resistance is gradually removed
torque. Really big motors have a tendency to have until the rated speed is achieved and the motor
a very low starting torque, sometimes even lower is working at the equivalent rate of a standard
than the rated torque. It is not possible to start squirrel-cage motor.
such a motor fully loaded not even at D.O.L The advantage of a slip-ring motor is that the
start. starting current will be lower and it is possible to
The rated torque of a motor can be calculated adjust the starting torque up to the maximum
using the following formula: torque.
9550 x Pr In general, if a softstarter is going to be used for
Mr = nr
this application you also need to replace the motor.
Mr = Rated torque (Nm)
Pr = Rated motor power (kW)
nr = Rated motor speed (rpm) 7
T
T rpm
Tst/Tn1.5...2.5 Torque diagram for a slip-ring motor
Tn
rpm
Torque diagram for a typical squirrel cage motor rpm
Current diagram for a slip-ring motor
Different starting methods
The following is a short description of the most common starting methods for
squirrel cage motors.

An overview of common problems when starting and stopping a motor with different
starting methods, see page 14
Direct-on-line start (D.O.L) Frequency converter
Start-delta start Softstarter

Direct-on-line start (D.O.L) The values are dependent on the design and size
of the motor, but in general, a smaller motor
This is by far the most common starting method gives higher values than a larger one.
available on the market. The starting equipment
consists of only a main contactor and thermal or During a direct-on-line start, the starting torque
electronic overload relay. The disadvantage with is also very high, and is higher than necessary for
this method is that it gives the highest possible most applications. The torque is the same as the
starting current. A normal value is between 6 to 7 force, and an unnecessary high force gives
times the rated motor current but values of up to unnecessary high stresses on couplings and the
9 or 10 times the rated current exist. Besides the driven application. Naturally, there are cases
starting current there also exists a current peak where this starting method works perfectly and
that can rise up to 14 times the rated current in some cases also the only starting method that
since the motor is not energised from the the first works.
moment when starting.
T Max. torque
Starting torque
9
KM 1 Rated torque
FR 1 rpm
Torque/speed curve att D.O.L start
I Max. starting current
M
D.O.L. starter with contactor Single line diagram
and O/L relay for a D.O.L.
KM 1 Main contactor
Rated current
FR 1 Overload relay
rpm
Current curve at D.O.L start
Star-delta start accelerate the motor up to speed before switching

over to the delta position.
This is a starting method that reduces the starting When starting up pumps and fans for example,
current and starting torque. The device normally the load torque is low at the beginning of the
consists of three contactors, an overload relay and start and increases with the square of the speed.
a timer for setting the time in the star-position When reaching approx. 80-85 % of the motor
(starting position). The motor must be delta rated speed the load torque is equal to the motor
connected during a normal run, in order to be torque and the acceleration ceases. To reach the
able to use this starting method. rated speed, a switch over to delta position is
The received starting current is about 30 % of necessary, and this will very often result in high
the starting current during direct on line start and transmission and current peaks. In some cases the
the starting torque is reduced to about 25 % of current peak can reach a value that is even bigger
the torque available at a D.O.L start. This starting than for a D.O.L start. Applications with a load
method only works when the application is light torque higher than 50 % of the motor rated torque
loaded during the start. If the motor is too heavily will not be able to start using the start-delta starter.
loaded, there will not be enough torque to
10
400 V
KM 2 KM 3 KM 1
230 V
KM 1 KM 2 KM 3
FR 1
M
FR 1
Star-delta starter with contactors and O/L relay Single line diagram for a Star-delta starter
KM 1 Main contactor
KM 2 Delta contactor
KM 3 Star contactor
FR 1 Overload relay
11
I
T
rpm rpm
Torque/speed curve at Star-Delta start Current curve at Star-Delta start

Frequency converter fact that there is no need for speed regulation

during a normal run. Of course this will create a
The frequency converter is sometimes also need for much more expensive starting equipment
called VSD (Variable Speed Drive), VFD than necessary.
(Variable Frequency Drive) or simply Drives, By controlling the frequency, the rated motor
which is probably the most common name. torque is available at a low speed and the starting
The drive consists primarily of two parts, one current is low, between 0.5 and 1.0 times the
which converts AC (50 or 60 Hz) to DC and the rated motor current, maximum 1.5 x In .
second part which converts the DC back to AC, Another available feature is softstop, which is
but now with a variable frequency of 0-250 Hz. very useful, for example when stopping pumps
As the speed of the motor depends on the where the problem is water hammering in the
frequency this makes it possible to control the speed pipe systems at direct stop. The softstop function
of the motor by changing the output frequency is also useful when stopping conveyor belts from
from the drive and this is a big advantage if there transporting fragile material that can be damaged
is a need for speed regulation during a continuous when the belts stop too quickly.
run. It is very common to install a filter together with
In many applications a drive is still only used the drive in order to reduce the levels of emission
for starting and stopping the motor, despite the and harmonics generated.
12
KM 1 Main contactor
Q1 Frequency converter
AC
DC
Q1
DC
AC
KM 1
M
Frequency converter Single line diagram for a frequency converter
Softstarter One of the benefits with this starting method is
the possibility to adjust the torque to the exact
A softstarter has different characteristics to the need, whether the application is loaded or not. In
other starting methods. It has thyristors in the principle the full starting torque is available, but
main circuit, and the motor voltage is regulated with the big difference that the starting procedure
with a printed circuit board. The softstarter makes is much more forgiving to the driven machinery,
use of the fact that when the motor voltage is low with lower maintenance costs as a result.
during start, the starting current and starting
torque is also low. Another feature of the softstarter is the softstop
During the first part of the start the voltage to function, which is very useful when stopping
the motor is so low that it is only able to adjust pumps where the problem is water hammering
the play between the gear wheels or stretching in the pipe system at direct stop as for star-delta
driving belts or chains etc. In other words, starter and direct-on-line starter.
eliminating unnecessary jerks during the start. The softstop function can also be used when
Gradually, the voltage and the torque increase stopping conveyor belts to prevent material
so that the machinery starts to accelerate. from damage when the belts stop too quickly.
13
KM 1 KM 1 Main contactor
FR 1 Overload relay
Q1 Softstarter
FR 1
Q1
M
Softstarter Single line diagram for a softstarter
Common problems when starting and stopping motors with

different starting methods
Type of problem Type of starting method

Direct-on-line Star-delta start Drives Softstarter
Slipping belts and Yes Medium No No
heavy wear on bearings
High inrush current Yes No No No
Heavy wear and tear Yes Yes No No

on gear boxes (loaded start)
Damaged goods / Yes Yes No No

products during stop
Water hammering in pipe Yes Yes Best Reduced

14 system when stopping solution
Transmission peaks Yes Yes No No
Auto transformer start and start of a part winding motor have similar problems to the star-delta start.
Different applications
All motors are used for starting and running different applications. This chapter
covers the most common ones. The different applications will also result in different
load conditions for the motor. There are two factors to consider:
1. Braking load torque, a direct braking force on the motor shaft. To be able to
accelerate, the motor has to be stronger than the load. The accelerating torque
is the difference between the available motor torque and the load toque.
Accelerating torque = Available motor torque – load torque
2. Involved moment of inertia or flywheel mass will also affect the start.
The bigger inertia the longer starting time for the same motor.
Centrifugal fan
T
Available
motor torque 15
Centrifugal pump
Accelerating
torque
Compressor
Braking load
(load torque)
Conveyor belt
rpm
Centrifugal fan
For some applications the motor is started with reduced load torque, i.e. unloaded
start. Big centrifugal fans are often started with a closed damper and this will make
the start easier (shorter) but since the moment of inertia is still present the starting
time might be quite long anyway.
Direct-on-line start The belts slip depending on whether the starting

torque from the motor is too high during the
Centrifugal fans are very often driven by one or start sequence and the belts are not able to
more drive belts. During a D.O.L start these belts transfer these forces. This typical problem gives
have a tendency to slip. The reason is that these high maintenance costs but also production
types of fans always have a more or less high losses when you need to stop production to
moment of inertia (big flywheel). So even if the change belts and bearings.
fan is started unloaded, the flywheel is still there.
T I
16
16
rpm rpm
Torque/speed curve at D.O.L start Current curve at D.O.L start

Star-delta starter (Y-D) Softstarter
The star-delta starter gives lower starting torque The key to solve these problems is to reduce the
but depending on the fact that the load torque starting torque from the motor during start.
increases with the square of the speed, the motor By using an ABB softstarter the voltage is
torque will not be high enough in the star position decreased to a low value at the beginning of the
to accelerate the fan to the rated speed. start, low enough to avoid slip but high enough
When switching over to delta position it will to start up the fan. The softstarter provides the
be both a high transmission and current peak, ability to adjust to fit any starting condition, both
often equal to values when making a D.O.L start unloaded and fully loaded starts.
or even higher, with a slipping belt as a result.
It is possible to reduce the slip by stretching the
belts very hard. This gives high mechanical
stresses on bearings both in the motor and the
fan with high maintenance costs as result.
T T
17
rpm rpm
Torque/speed curve at Star-Delta start Torque/speed curve when using a softstarter
I I
rpm rpm
Current curve at Star-Delta start Current curve when using a softstarter
Selection of a suitable
softstarter
Normal start
For fans with small or medium large flywheels,
select a softstarter according to the rated motor
power.
The above is valid if the time for D.O.L start
is less than 5 seconds.
Heavy duty start Recommended basic settings:
For fans with large flywheels, select a softstarter Start ramp: 10 sec.
designed for heavy duty start according to the Stop ramp: 0 sec.
rated motor power. It is also possible to select a Initial voltage: 30 %
softstarter for normal start, select a unit with one Current limit is recommended for use.
size bigger power rating than the motor and use
an overload relay class 30.
The above is valid if the time for D.O.L start
is more than 5 seconds.
18
18
Application with a centrifugal fan

Centrifugal pump
There are a lot of different types of pumps; like piston pumps, centrifugal pumps,
screw pumps etc. But the most common version is the centrifugal pump and we
have selected this one to describe.
Direct-on-line start
Starting up a pump is normally not a problem
for a squirrel cage motor. The problem is the
wear and tear depending on pressure waves in
the pipe system created when the motor starts
and stops too quickly. During a D.O.L start the
motor gives much too high starting torque
with the result that the motor accelerates and
reaches nominal speed too quickly. The reason
is that the braking load torque is low for a pump
during start. This starting method also gives
maximum possible starting current. 19
T I
rpm rpm

Star-delta starter (Y-D) When stopping a pump

By using a star-delta starter it is possible to During stop it is also normal to have problems.
reduce the starting torque. The motor torque When making a direct stop by disconnecting
in the star position is too weak to be able to the main supply the motor stops too quickly.
complete the start and reach the rated speed. Depending on high mass flow in the pipe system
the water will continue with the same speed for
The quadratic load torque will become too high
a short period and then come back again,
for the motor when reaching approx. 80-85 % of
backwards in the pipe system. This creates high
the rated speed and the switch over to the delta
pressure shocks on valves and gives high
position will give both high transmission and
mechanical stresses on the pipe system.
current peaks with pressure waves as a result.
The current peaks can be equally high as at a
D.O.L start or even higher.
I
T
20
20
rpm rpm
Torque/speed curve at Star-Delta start Current curve at Star-Delta start
Softstarter Also during the stop sequence the softstarter is
the solution. The softstarter reduces the voltage
By using an ABB softstarter the voltage is reduced during stop via a voltage ramp and the motor
during the start sequence with the result that the becomes weaker and weaker. Because of this the
motor torque is reduced. During the start water speed slows down very smoothly without
sequence the softstarter increases the voltage so creating any pressure waves.
that the motor will be strong enough to accelerate A special function on the softstarter is sometimes
the pump to the nominal speed without any available, called "step-down voltage",which ensures
torque or current peaks. A normal starting an optimum setting to the actual need for any
current with a softstarter when starting a fully pipe system.
loaded centrifugal pump is approx. 4 times rated
motor current.
I
T
21
rpm rpm
Torque/speed curve when using a softstarter Current curve when using a softstarter
softstarter
Normal start
Starting a pump is a typical normal start
condition.
Select a softstarter according to the rated
motor power. Recommended basic settings:
Start ramp: 10 sec.
Heavy duty start Stop ramp: 20 sec.
Not applicable for this application. Initial voltage: 30 %
22
22
Application with a pump.

Compressor
Smaller compressors are often of piston type and the load torque increases linearly
with the speed. Screw compressors are often used when there is a bigger need for air
flow and this type has a load torque increasing with the square of the speed.
Drive belts are often used between motor and compressor but direct connections via
some type of toothed couplings are also common. Some compressors are started with
reduced load.
Direct-on-line start (D.O.L) drive belts are used the belts very often slip
during start. The high starting torque received
Compressors started direct-on-line are exposed during starting with this method is the source
to high mechanical stresses on the compressor of the problems. The starting current is always
itself, but also on drive belts and couplings. The high at D.O.L start. A normal value can be
result is shortened endurance. In cases where the approx. 7 times rated motor current.
T I
23
rpm rpm
Star-delta starter (Y-D) will occur with high mechanical stresses as a

result. Compressors are very often running at
Star-delta start gives a lower starting torque and no load condition for longer periods when the
starting current but the motor is too weak during pressure in the system is high. A motor running
the start up to be able to accelerate the motor under these circumstances always has a poor
up to nominal speed. When switching to the power factor and low efficiency. Some times the
delta position both current and torque peaks value is so low that it must be compensated.
T I
24
24
rpm rpm
Torque/speed curve at Star-delta start Current curve at Star-delta start
Softstarter
By using an ABB softstarter it is possible to
limit the starting torque to a level suitable for
all different applications. The result is less stress
on couplings, bearings and no slipping belts
during start. The maintenance cost will be
reduced to a minimum. When using a softstarter
the starting current received is approx. 3 to 4
times the rated motor current.
I
T
25
rpm rpm
Torque/speed curve when using a softstarter Current curve when using a softstarter
softstarter
Normal start
For compressors with D.O.L starting time less
than 5 seconds, select a softstarter according to
the rated motor power.
Heavy duty start
For compressors with D.O.L starting time more
than 5 seconds, select a softstarter designed for
heavy duty start according to the rated motor
power. Recommended basic settings:
It is also possible to select a softstarter for Start ramp: 10 sec.
normal start, select a unit with one size bigger Stop ramp: 0 sec.
power rating than the motor and use an overload Initial voltage: 30 % (piston compressor)
relay class 30. 40 % (screw compressor)
26
26
Application with a compressor

Conveyor belt
Conveyor belts can have a lot of different looks and directions of use. It is a typical
constant torque load with low to high braking torque depending on how heavy it is loaded.
Direct-on-line start (D.O.L) the driving role depending on this high starting
torque.
Conveyor belts often need a starting torque very Gearboxes and couplings are also exposed to high
near or just above the rated torque of the motor. mechanical stresses. This result is considerable
A direct-on-line start with a normal squirrel cage wear and tear and often high maintenance costs.
motor gives approx. 1.5 to 2.5 times rated torque Sometimes fluid couplings are used to reduce the
of the motor depending on motor size, type etc. transferred torque. This method is expensive and
When making a direct-on-line start there is a requires a lot of maintenance.
very high risk of slipping between the belt and
Low braking torque High braking torque
T T
27
rpm rpm
Torque/speed curve at D.O.L start Torque/speed curve at D.O.L start
I I
rpm rpm
Current curve at D.O.L start Current curve at D.O.L start
Star-delta start
It is not possible to use this starting method
when the load torque is close to the rated motor
torque during start (see figure below, High
braking torque).
T T
28
28
rpm rpm
Torque/speed curve at Star-delta start Torque/speed curve at Star-delta start
I I
rpm rpm
Current curve at Star-delta start Current curve at Star-delta start
Softstarter
By using an ABB softstarter the starting torque gearboxes and couplings and no slipping belts
can be reduced to a minimum value still able to during start. This will reduce the maintenance
start up the conveyor belt. The setting possibility cost to a minimum. When using a softstarter
of the softstarter makes it possible to adjust the you will receive approx. 3 to 4 times rated motor
torque to exactly the level that is necessary for current during start.
the start. The result is the least possible stress on
T T
29
rpm rpm
Torque/speed curve when using a softstarter Torque/speed curve when using a softstarter
I
I
rpm rpm
Current curve when using a softstarter Current curve when using a softstarter
softstarter
Normal start
A start of short and light loaded conveyor belt is a
typical normal start.
For conveyors with D.O.L starting time less
than 5 seconds, select a softstarter according to
the rated motor power.
Heavy duty start Recommended basic settings:
Conveyor belts can in some cases be very long and
if the belt is fully loaded during start the starting Start ramp: 10 sec.
time can be very long. For such applications select Stop ramp: 0 sec.
a softstarter designed for heavy duty start. It is also (If fragile material use 10 seconds)
possible to select a softstarter for normal start if Initial voltage: 40 %
the softstarter is chosen one size larger than the
rated motor power and use an overload relay
class 30.
30
30
Application with a conveyor belt

How to select a softstarter for
different applications
How to select a softstarter

It is normally possible to select a softstarter according to the rated motor power. In
some cases it is neccessary to select a larger softstarter than the rated motor power
depending on the starting conditions (heavy duty start, many starts/h etc.) The
starting capacity of a softstarter is very much depending on the thyristor capacity and
the heat sink.
The table below can be used as a guide to select a softstarter if you need a quick
answer and you want to be sure that the size is large enough to suit the application.
This selection will not give the most optimized solution.
If an opimised solution is required, the software selection program ”ProSoft”
for selection of softstarters can be used, available on www.abb.com/lowvoltage.
Quick guide
Normal start Heavy duty start
Typical applications Typical applications
31
»Bow thruster »Centrifugal pump »Centrifugal fan »Conveyor belt (long)
»Compressor »Conveyor belt (short) »Crusher »Mill
»Elevator »Escalator »Mixer »Stirrer
Selection Selection
Select the softstarter according to the For softstarters designed for nomal start,
rated motor power. select one size larger than the rated motor
For units with built-in overload, select power.
trip class 10. For softstarters designed for heavy duty
start, select according to the rated motor
power.
For units with built-in overload, select trip
class 30.
If more than 6 starts /h

Select one size larger than the selection above.
32
Description of the softstarters
- Design, settings and signals
Description of the softstarter

A softstarter in general is built up with a few main components such as a printed
circuit board (PCB), heat sink, thyristors, fans and housing (plastic or metal).
The controlling circuits can be of digital type, analogue type or a combination of
these. The output signal relays can be of a type with fixed function or as a free
programmable type where the user can decide upon the output function.
The softstarter is sometimes equipped with a built-in electronic overload relay
(EOL) replacing the conventional bi-metal relay which is normally used.
A built in EOL has much better accuracy than a conventional relay, since the values
are calculated electronically and this is especially useful when on intermittent duty.
The need for communication between different devices in a plant and from the
devices to a control board is increasing all the time. Many of today’s softstarters are
equipped with a port for such communication, which normally consists of a few
fibre optic cables instead of former solutions, which often reqired hundreds of 33
thousands of wires. Many different communication protocols exist today and some
of them are more common than others, for example Modbus, Profibus, DeviceNet,
Interbus-S, LON Works and so on.
Description of different components:
Description of components
Housing
Printed circuit board
34
Main terminals
Thyristor
Heat sink
Fan
Housing
Description of components
Printed circuit board is used to Housing can be made of plastic material,
control the firing of the thyristors based on the metal or a combination of these, and its function
current and voltage references, and also for the is to protect the inside components from
calculation of different values, for example the mechanical and electrical damage. It is also used
power factor, active power, etc. It can also be to protect the components from dust and dirt.
used for storing historical data, the event log, For total outside protection from dust and dirt
indicating trends and much more. a separate enclosure is often required since the
degree of protection (IP class) of the unit itself
Heat sink is used to get rid of the heat in is too low.
the softstarter generated by the current during
the start and the continuous run. The capacity Thyristors are semi-conducting
of the heat sink very much reflects the starting
components connected in an anti-parallel fasion
capacity and the operational current of the
and placed in two or three phases of the main
softstarter.
circuit. They regulate (by increasing or decrea-
Fans are used to increase the cooling sing) the level of voltage during start and the
capacity of the heat sink. One, two or several stop ramp, as described in the picture below.
fans can be used depending on size and design. During a continuous run the thyristors are
Some smaller softstarters don’t have fans at all conducting fully.
and the number of starts may be limited.
35
Zero crosses
Firing angle
Start: The thyristors let part of the voltage through at the beginning and
then increase it, according to the set ramp time for the start.
Stop: The thyristors are fully conducting and when soft stopping, they
decrease the voltage according to the set ramp time for stop.
Off : Thyristor is non-conducting
On : Thyristor is conducting
Common settings
Common settings
This section includes a short description of some common setting parameters

available on most of the softstarters. Other settings may be available depending
on the type of softstarter and manufacturer. The setting can be done either by
adjusting potentiometers, changing dip switches, using a key pad, a computer or
similar.
Start ramp is the time from were the Initial voltage. Sometimes named
softstarter start its ramp (initial voltage) until pedestrian voltage or torque, this is the point
full voltage is reached. The ramp time should from where the softstarter starts or stops its ramps.
not be too long, as this will only result in The torque of the motor will drop with the
unnecessary heating of the motor and a risk square of the voltage and if the voltage is set
of the overload relay to trip. If the motor is too low, for example 20 %, the starting torque
unloaded the start time for the motor will will become 0.22 = 0.04 = 4 % only, and the
probably become shorter than the set ramp motor will not start from the very beginning.
time, and if the motor is heavily loaded, the Therefore it is very important to find a level
start time will probably become longer. that is just high enough to make the motor take
off directly to avoid unnecessary heating.
Stop ramp is used when a soft stopping
36 of the motor is required, for example a pump
or a conveyor belt. The stop ramp is the time
from full voltage until stop voltage (initial
voltage) is reached. If the ramp time is set to
zero the stop will be like a direct stop.
Ue
Initial voltage
(U )
ini
Time
Start ramp Stop ramp
Diagram showing start ramp, stop ramp and initial voltage

Common settings
Current limit can be used in applications
where a limited starting current is required, or
at a heavy-duty start when it is difficult to
achieve a perfect start with the setting of the
initial voltage and the start ramp only. When
the current limit is reached, the softstarter will
temporarily stop increasing the voltage until the
current drops below the set limit, and then
continues ramping up to full voltage.
Note that this feature is not available on

all softstarters.
U
100 %
fixed voltage
reached set level
of current limit
37
30 %
t1 t2 Time
t1 + t2 = set ramp time
set level of
current limit
Time
Current limit function in softstarter use
Step down voltage gives a special Adjustable rated motor
Common settings
type of stop ramp. It is possible to adjust the current makes it possible to set the motor
voltage to drop to a level where the speed of
rated current on the softstarter for the used motor.
the motor starts to reduce immediately at the
This setting may affect other values as well, such
stop command. For low loaded motors the
as the trip level of the electronic overload relay,
speed will not reduce until a very low voltage
the level of the current limit function and so on.
is reached, but using the step down voltage
function can eliminate this phenomenon and
is especially useful for stopping pumps.
Step down voltage = U

SD
U
100 %
38 Example 50 %
Initial voltage 30 %
(= end voltage 30 %)
30 %
Stop Time
Curve showing the step down voltage function

Different indications
Different indications
The indications on a softstarter differ very much from one type to another and also between
manufacturers. Some of the most common indications are described below.
On normally indicates that the power supply Overload indicates that the overload
is connected to the softstarter and that the unit protection has tripped. The reason for a tripping
is ready to start the motor. overload can be too high motor current, too long
starting time, too many starts after each other,
Top of Ramp indicates that the start wrong set overload, wrong trip class of overload
ramp is completed and full voltage is reached. or a combination of these.
If a by-pass contactor is used it will be activated
at this point. Overtemperature indicates that the
softstarter unit is over-heated, due to the number
Fault indication can be of many different of starts exceeded, too high-rated current, too
types. One is if there is an internal fault on the long starting time or similar.
softstarter itself, a fault on the feeding side (phase
loss, blown fuse or similar) or on the motor side
(motor not connected, phase missing etc.)
39
Different voltages
Different voltages
Different named voltages are used for the softstarters. The name and use of these
different voltages is stated in the IEC-standard as below.
Main Voltage (Ue), Control Voltage (Uc),

which is the voltage feeding the motor and which is the voltage for controlling the start
also the voltage exposed to the main circuit and stop command of the softstarter.
(thyristors) in the softstarter. 200 - 690 V Values between 24 - 480 V exist.
are normal values.
Supply voltage (Us),

which is the voltage feeding the electronic
components inside the softstarter, for example
the printed circuit board.
Common values are 110 - 120 V or 220 - 240 V.
Main Voltage (Ue) Main Voltage (Ue)

40
Internal
supply L1 L2 L3 L1 L2 L3
Control Start Power (Internal
Start Power Supply
supply
Voltage (Uc) Stop supply power
Stop Voltage (Us) supply)
T1 T2 T3 T1 T2 T3
M M
Main voltage and supply voltage to a softstarter Main voltage and control voltage to a softstarter
Ambient temperature
Ambient temperature
The ambient temperature is the average Example 1
surrounding temperature of the softstarter over a Rated current: 105 A
period of 24 hours. For most types of softstarter Ambient temperature: 48 oC
the temperature may not exceed 40 oC without Derating with 0.8 % per oC above 40 oC
derating the operational current for the unit. (PS S 18...300)
The maximum ambient temperature during
operation differs from one type of softstarter ∆ T = 48-40 oC = 8 oC
to another and must be checked individually New current = Ie - (∆ T x Ie x 0.008) =
according to the manufacturer’s specification. 105 - (8 x 105 x 0.008) = 98,2 A
When using an ABB softstarter with an
ambient temperature of above 40 oC, the Example 2
following formula can be used to calculate Rated current: 300 A
the operational current: Ambient temperature: 46 oC
Derating with 0.8 % per oC above 40 oC
(PS S 18...300)
I e derated = I e - (∆ T x I e x 0.008)
Ie derated = maximum operational current ∆ T = 46-40 oC = 6 oC
after derating New current = Ie - (∆ T x Ie x 0.008) =
Ie = rated current of the softstarter 300 - (6 x 300 x 0.008) = 285.6 A
∆T = temperature difference 41
0.008 = derating factor
Derating when used at high
altitudes
High altitudes
When a softstarter is used at high altitudes the Example:

rated current for the unit has to be derated, due Softstarter with rated current 300 A used at
to less cooling. For most manufacturers the 2500 meter above sea level.
catalogue values are valid up to 1000 m above
2500 - 1000
sea level before derating is necessary. % of Ie = 100 - =
150
In some cases a larger softstarter is required to 1500
be able to cope with the motor current when = 100 - = 90
150
used at high altitudes.
For ABB softstarters the following formula Ie = 300 x 0.9 = 270 A
can be used for calculating the derating:
% of Ie = 100 - x - 1000 The diagram below can also be used for

150
defining the derating of the softstarter.
x = actual altitude for the softstarter
42
% of Ie
100 %
90 %
80 %
1000 2000 3000 4000 m

meter above sea level
Derating of motor current at high altitudes
Start of several motors

In some applications, more than one motor will be started with one softstarter,
in parallel with each other or in a sequence. This is often possible to do but some
data has to be taken into consideration.
Parallel start of motors

If a softstarter is going to be used for starting
several motors at the same time (parallel start),
there are two important parameters to check:
1. The softstarter must be able to cope with KM 1 KM 1 Main contactor
the rated current for all motors together. FR 1 Overload relay
Q1 Softstarter
2. The softstarter must be able to cope with
the starting current for all motors together
FR 1
until rated speed is achieved.
Note! If a by-pass contactor is used for

the softstarter, only point 2 above has
Q1
to be taken into consideration.
43
Example:
Start of two motors with Ie = 100 A and
relative starting current 4 x Ie.
Starting time is 10 seconds.
Total starting current is 100 x 4 x 2 = 800 A M M
over 10 seconds.
Parallel start of motors using a softstarter
Check the softstarter starting capacity graph to
verify the selected size.
Sequential start of motors The starting current for the motors is 100 x 4 =
400 A and the total starting time is 5 + 10 + 8 =
If a softstarter is going to be used for starting 23 seconds.
several motors one by one (sequential start), it Check the softstarter starting capacity graph
is important to check that the softstarter is able to verify the selected size.
to cope with the starting current for each motor
during the whole starting sequence. Note! It is not possible to add the starting
Example: time for each motor if the rated current
Start of three motors with Ie=100 A and is different from one motor to another. A
relative starting current 4 x Ie. separate calculation has to be made for
Starting time for the motors is: those applications.
Motor 1 = 5 seconds
Motor 2 = 10 seconds
Motor 3 = 8 seconds KM 1 Main contactor
K 25, 27, 29 Starting contactor
K 26, 26, 30 Run contactor
FR 1, 2, 3 Overload relay
Q1 Softstarter
KM 1
44
Q1 K 26 K 28 K 30
K 25 K 27 K 29
FR 1 FR 2 FR 3
M M M
Sequential start of motors using a softstarter
Different ways of connecting the
softstarter
Different ways of connecting

There are two different ways of connecting the softstarter - In line, which is the
most common method, and Inside Delta. Note that only a few types of softstarters
can actually be connected Inside Delta for example the ABB softstarter range
PS S 18/30...300/515.
45
In line Inside Delta

In-line connection Inside Delta connection
This is easily the most common way to connect The Inside Delta connection makes it possible
the softstarter. to place the softstarter in the delta circuit and
All three phases are connected in a series with in that way it can easily replace an existing
the overload relay, the main contactor and other Y/D-starter.
devices used just like the diagram below. When the softstarter is Inside Delta it will
The selected devices for Inline connection must only be exposed to 58 % (1/√3) of the In-line
be chosen to cope with the rated motor current. current. Therefore it is possible to downsize the
Example: 100 A motor requires a 100 A devices in order to achieve a more cost-effective
softstarter, 100 A main contactor etc. solution.
Example: A 100 A motor requires a 58 A
softstarter, a 58 A main contactor if placed in
the delta circuit, etc.
A motor used for an Inside Delta connection
must be able to delta-connect during a continuous
run. In the USA and some other countries a
special six-wire motor has to be ordered for this
type of connection.
46
100 A 100 A
100 A
100 A
58 A
100 A 58 A
58 A
M M
100 A 100 A
Softstarter connected In-line with the motor Softstarter connected Inside Delta
Location of the main contactor
When using the softstarter Inside Delta there
are two options for the main contactor: in the
delta circuit or outside. Both locations will stop
the motor but in alternative A, the motor is still
considered to be under tension.
In alternative B the main contactor must be
chosen according to the rated current of the
motor, while the contactor in alternative A can
be chosen according to 58 % (1/√3) of the
rated current.
x x
47
B
M M
Alternative A Alternative B
Main contactor located in the delta circuit Main contactor located outside the delta circuit
48
Basic settings for different
applications
Basic settings
The required settings for the softstarter will differ from one application to another
depending on the type of load, motor characteristics, how much the motor is
loaded, etc.
For a more in depth description of each setting, please see chapter ”Description
of the softstarters”.
Note ! All settings on next page are only proposals and may change from one application
to another and therefore need to be checked individually.
49
Basic settings
Settings when using a softstarter without current limit function
Type of load Ramp time for Ramp time Initial voltage

start (sec.) for stop (sec.) Uini
Bow thruster 10 0 30 %
Centrifugal fan 10 0 30 %
Centrifugal pump 10 20 30 %
Centrifuge 10 0 40 %
Conveyor belt 10 01) 40 %
Crusher 10 0 60 %
Escalator 10 0 30 %
50 Heat pump 10 20 30 %
Hydraulic pump 10 0 30 %
Lifting equipment 10 10 60 %
Mill 10 0 60 %
Piston compressor 10 0 30 %
Rotary converter 10 0 30 %
Scraper 10 10 40 %
Screw compressor 10 0 40 %
Screw conveyor 10 10 40 %
Stirrer, Mixer 10 0 60 %
Unloaded motor 10 0 30 %
1) If fragile material, use 10 seconds.

Basic settings
Settings when using a softstarter with current limit function
Type of load Ramp time for Ramp time Initial voltage Current limit
start (sec.) for stop (sec.) Uini ( x Ie)
Bow thruster 10 0 30 % 3
Centrifugal fan 10 0 30 % 4
Centrifugal pump 10 20 30 % 3.5
Centrifuge 10 0 40 % 4.5
Conveyor belt 10 01) 40 % 4
Crusher 10 0 60 % 5
Escalator 10 0 30 % 3.5
Heat pump 10 20 30 % 3.5 51
Hydraulic pump 10 0 30 % 3.5
Lifting equipment 10 10 60 % 4
Mill 10 0 60 % 5
Piston compressor 10 0 30 % 4
Rotary converter 10 0 30 % 3
Scraper 10 10 40 % 4.5
Screw compressor 10 0 40 % 4
Screw conveyor 10 10 40 % 4
Stirrer, Mixer 10 0 60 % 5
Unloaded motor 10 0 30 % 2.5
1) If fragile material, use 10 seconds.

Starting capacity and overload
protection
Starting capacity
Starting capacity for soft- Heavy duty applications normally require

a starting current between 4 and 5 times the
starters rated motor current.
When starting a squirrel cage motor there will The maximum permitted starting current for
always be a starting current (I st) which is a softstarter depends on the starting time. The
higher than the rated motor current. ratio between the current and time is displayed
The starting current depends on what type of in the graph below.
starting method is used and in some cases also A higher starting current will give a shorter
the size of the motor, particular at D.O.L-start. possible starting time, for example a crusher
For a softstarter a normal value is 3-4 times the application. A lower current will allow a longer
rated motor current. starting time, for example a pump application.
52
Time
Sec.
1000
100
10
1 Starting
100 200 300 400 A current
Typical starting capacty graph for a softstarter

Starting capacity
Starting capacity when using Starting capacity when using
by-pass contactor overload protection
When using a softstarter with a by-pass contactor The overload protection for the motor (thermal
it is sometimes possible to select a softstarter with or electronic) will very often set the limit of the
a lower rated power than the motor rated power starting capacity. A class 10 relay is used for
since the softstarter will be working during start normal starts in general while a class 30 relay is
and stop only, not continuously. used for heavy-duty starts where a longer star-
The softstarter can not withstand the rated ting time must be used.
motor current and therefore a check of the star- In some applications where the overload
ting capacity must be carried out for the selected protection is by-passed (other protection active)
size. during a start to achieve a longer available
starting time, it is particularly important to
check the softstarter starting capacity since this
will be the limitation.
Time
53
b
a
Starting
current
a) Tripping curve for overload protection
b) Max starting capacity for a softstarter (This will limit the starting time / current if the overload is
by-passed during start)
Number of starts/hour
The maximum number of starts/hour for a softstarter depends on several different
Number of starts/hour
factors such as the starting current, ambient temperature, starting time and the
intermittens factor.
Intermittens factor Examples:

The intermittens factor is a figure indicating If a softstarter has been running for 5 minutes
how long the softstarter has been running of a total duty cycle of 10 minutes then the
for (starting time and running time) compared intermittens factor is 50 % ON time and 50 %
with the total cycle time. OFF time.
It is important to define the intermittens If a softstarter has been running for 45
factor when talking about the number of starts/ minutes of a duty cycle of 60 minutes then
hour since the OFF time is the cooling time for the intermittens factor is 75 % ON time and
the softstarter. 25 % OFF time.
A high starting current and a long starting time
require a longer OFF time than a low starting
current and short time to maintain the same
number of starts/hour.
54
Duty cycle
On Off
on Time
Intermittens factor = x 100 %
on + off
Harmonics
Harmonics
Harmonics are unwanted voltages and currents existing in almost every electrical
system today and are always a multiple of the rated frequency.
Typical harmonics are 3rd, 5th, 7th, 9th etc. The harmonics contribute to the
unnecessary heating of motors, cables and other equipment and may shorten the
lifetime of these devices if exposed for a long period of time.
It can sometimes also disturb functions on electronics and systems. The harmonic
contents and the level naturally depends on the source but also on several other
parameters such as the impedance in the feeding network, the motor, capacitors and
other devices used in the system altogether - in other words a quite complex
phenomenon.
Harmonic content and

softstarters
The question of harmonic content for softstarter
applications is actually in general not relevant
at all. These reflections usually come from 55
55
drive applications where harmonics are generated
continuously and a filter is always required in
public networks and very often used also in
industrial networks. With our softstarters we
fulfil the EMC directive concerning emission
and immunity and there is no need for any
particular actions regarding this matter at all.
Explosive atmospheres (Ex)
For plants in environments where the hazard of explosion is due to an explosive
Explosive atmospheres
mixture of gases, explosive matter or combustible dust other than explosive dust,
special provisions are applicable regarding the use of electrical material. For electrical
motors there are two main principles for explosion protection. One is to design
the motor so that no sparks or dangerous heat occurs. The other method is to isolate
sparks and dangerous heat inside the motor to prevent ignition of any explosive
mixture of gases outside the motor.
The different classes of explosive protection (Ex) are described by the following parts of
IEC 60079:
IEC 600079-1: flameproof enclosures ”d”
IEC 600079-2: pressurised enclosures ”p”
IEC 600079-5: powder filling ”q”
IEC 600079-6: oil immersion ”o”
IEC 600079-7: increased safety ”e”
56 IEC 600079-11: intrinsic safety ”i”
IEC 600079-18: encapsulation ”m”
IEC 600079-22: caplights for mines susceptible to firedamp (under consideration)
Example: Electrical apparatus for explosive atmospheres - oil immersion ”o” shall be recognised as Exo.
Explosive atmospheres
Hazardous areas and zones Location and selection
The hazardous areas are categorised in of softstarter for Ex
zones as follows: environments
Zone 0 If a softstarter is going to be used for an Ex
application it is normally located in a separate
An area in which an explosive gas atmosphere is
enclosure outside any of the hazardous zones.
present continuously or for long periods. Only
The overload relay used shall be of a special
intrinsically-safe circuits of category Exi may be
version designed for EEx motors, for example
used in this zone. Motors are thus excluded.
TA 25 DU...V 1000 to T 900 DU/SU...V 1000.
Zone 1 This type of relay has a more accurate tripping
curve compared with the standard relay. Special
An area in which an explosive gas atmosphere is
attention has to be paid to this.
likely to occur in normal operation. Motors of
category Exd, Exe and Exp may be used in this The softstarter type and size and other devices
zone. used in the circuit shall suitably be selected
according to type 2 co-ordination.
Zone 2
An area in which an explosive gas atmosphere is Note !
not likely to occur during normal operation and If any electrical equipment is going to be
used in any of the hazardous zones a special
57
57
if it does occur it will exist for a short period
only. Equipment permitted in zones 0 and 1 enclosure must be used. This type of
may of course be used. Under certain conditions enclosure (steel box or similar) must be
the equipment, motors for instance, need not to able to withstand an inside explosion
be of explosion-protected design. caused by any of the components without
letting anything out to the surroundings.
3m r4.5 m This solution is in general very unusual.
3m
Surface of liquid
Height
of wall
Low point To wall
Zone 0 Zone 1 Zone 2
Example of classification and extent of the hazardous area in a tank

Co-ordination
By co-ordination we mean a selected combination of electrical apparatus which is
Co-ordination
safe for the surroundings and personnel, even if an overload or a fault should occur
in the system.
The co-ordinated group must ensure the following four essential functions:
• Protection against overloads. A protection, which guards all components, cables
and the motor from overheating, active for all currents up to, locked rotor current.
This device will send a trip signal to a disconnection mean, which is normally a
contactor used for the motor control.
• Motor control. This function is commonly carried out by a contactor.
• Protection against short-circuits, which takes care of all currents above the locked
rotor current - i.e. all fault currents.
• Isolation. Ensure an isolating air-gap when opened for personnel safety.
The co-ordinations for the ABB softstarters are done according to IEC 60947-4-2
”AC semiconductor motor controllers and starters” and EN 60947-4-2.
58 The provisions of IEC 60947-1, General Rules, are applicable to IEC 60947-4-2
where specifically called for.
Co-ordination
Types of co-ordination Type 2:
The standard IEC 60947-4-2 defines two types Co-ordination requires that, under short-circuit
of co-ordination according to the expected level conditions, the device shall cause no danger to
of service continuity. The standard IEC 60947-1, persons or installation and shall be suitable for
General Rule are applicable to this standard, further use. For hybrid controllers and starters,
where specifically called for. the risk of contact welding is recognized, in
which case the manufacturer shall indicate the
Type 1: measures to be taken as regards the maintenance
Co-ordination requires that, under short-circuit of the equipment.
conditions, the device shall cause no danger to
persons or installation and may not be suitable Note !
for further service without repair and replacement When using a softstarter in a type 2
of parts. co-ordination, replacing the fuses and
restart has to be accepted after a short-
circuit. Only semi-conductor fuses can
be used to achieve a type 2 co-ordination
for a softstarter.
59
59
Co-ordination
Utilization Categories
Some utilization categories are stated in the standard IEC 60947-4-2, ”AC semiconductor
motor controllers and starters”. The one used for ABB Low Voltage softstarters is AC-53.
Utilization Typical application

Category
AC-52a Control of slip-ring motor stators: 8 h duty with on-load currents for
start, acceleration, run
AC-52b Control of slip-ring motor stators: intermittent duty
AC-53a Control of squirrel cage motors: 8 h duty with on-load currents for
start, acceleration, run
60
AC-53b Control of squirrel cage motors: intermittent duty
AC-58a Control of hermetic refrigerant compressor motors with automatic resetting of

overload releases: 8 h duty with on-load currents for start, acceleration, run
AC-58b Control of hermetic refrigerant compressor motors with automatic resetting of

overload releases: intermittent duty
Remarks
AC-53 is the utilization category used for softstarters in general since this is about
controlling squirrel cage motors. This is the category stated in the header of the
co-ordination tables for softstarters.
AC-53a is about softstarter designed for use without by-pass contactor.
AC-53b is about softstarter designed for use with by-pass contactor.
Co-ordination
Types of fuses
There are basically three types of fuses used on the market (see below) with different
functions and characteristics. One type of fuse cannot in general replace another
type without checking the other protection devices in the circuit since the protection
characteristic of the fuse is different between the types. If replacing a 100 A fuse with
another 100 A fuse (same rating) without checking the type there is a risk of losing
protection since the first type may be of type with both short-circuit protection and
thermal protection while the replacement fuse is only short-circuit protection.
gL/gG fuses have a combination of short circuit

protection and thermal overload protection
(5s > 3,5 x In) for cables.
If using these types of fuses together with a
softstarter, type 1 co-ordination can be achieved. Time
For type 2 co-ordination semi-conductor fuses
must be used. a
aM fuses have only a short-circuit protection 61
61
b c
(5s > 9 x I n), and for thermal overload
protection a separate protection device is
required.
If using these types of fuses together with a d
softstarter, type 1 co-ordination can be achieved.
For type 2 co-ordination semi-conductor fuses
must be used. Current
Semi-conductor fuses (High speed fuses) are a: Characteristic of the overload relay
the only type of fuses that are fast enough to b: Characteristic of a gL/gG fuse
achieve a fully type 2 co-ordination when c: Characteristic of a semi-conductor fuse
using a softstarter. A separate overload relay d: Area where the gL/gG fuse is not fast enough
for the motor protection is always required to achieve a type 2 co-ordination
in combination with this type of fuse. If
replacing the semi-conductor fuses with an
MCCB, MMS or similar, type 1 co-ordination
will be achieved instead.
Co-ordination
Where to find the co-ordination tables

The co-ordination tables for softstarters can be found on internet page www.abb.com
under Low Voltage Products - Product Coordination.
When selecting the wanted product type, for example softstarters the table below
will show up.
Ue Main voltage for the application
Iq Short-circuit current rating
Coor. Type Type of co-ordination
Starting type Type of start, normal or heavy duty
SCPD type Type of protection device
Size kW Rated motor power range
62 Table Name of the co-ordination table (click on the text to open)
Last Update Latest date of table update
Example of starter range, Ue= 400 - 500 V.

How to read the co-ordination tables
Co-ordination
In the header of the selected table, information about softstarter type, main voltage, short-
circuit rating, maximum ambient temperature, IEC-standard and co-ordination type can be
found.
Motor Indicates the rated output of the motor and maximum current.
If this does not correspond fully to the actual motor, select according
to the maximum current.
Softstarter Indicates suitable softstarter type and size for this motor.
Semi-conductor fuses Indicates rated current and type of semi-conductor fuse.
Switch fuse Indicates suitable switch fuse for the semi-conductor fuses.
Thermal overload relay Indicates suitable thermal overload relay, type and setting range.
Line contactor Indicates suitable line (main) contactor for the motor. 63
63
This contactor is given with AC-3 rating.
By-pass contactor Indicates suitable by-pass contactor which is not required for the
co-ordination. This contactor is given with AC-1 rating.
Example of co-ordination table: 500V, 65kA, normal start, type 2 (PSD5065LINE40)

Starter and fuses In-line Starter Inside Delta and
Co-ordination
fuses In-line
The co-ordinations with the devices In-line are The co-ordinations with the softstarter Inside
based on this circuit diagram. Delta are based on this circuit diagram.
Note that the by-pass contactor is not Note that the by-pass contactor is not
required for the co-ordination. required for the co-ordination.
64 Switch fuse
Switch Fuse
Semi-conductor fuse
Semi-conductor fuse
Line contactor
O/L relay
Line contactor
Softstarter By-pass Softstarter By-pass

contactor contactor O/L relay
Motor
M Motor M
Starter and fuses In-line Starter inside delta and fuses In-line
Line contactor AC-3 Line contactor AC-3
By-pass contactor AC-1 By-pass contactor AC-1
Line contactor and by-pass contactor Inside Delta
connected
ESD – Electro Static Discharge
ESD - Electro Static Discharge

An increasing problem today with the use of more and more electronic equipment in
our systems is the Electro Static Discharge (ESD). The main source of the problem is
the wrong handling of electronic components, printed circuit-boards, etc. A component
damaged by ESD has been exposed to a too high voltage level and today the components
are much more sensitive depending on integration, which means more functions in
the same capsule. The distances between the conductors are decreased and therefore
the insulation distance will be at a minimum. A value of 0.002 mm is common in
modern integrated circuits.
Electro static charge is caused in three different ways:

• Rubbing of two surfaces to each other.
• Separation of two surfaces from each other, for example when removing a plastic cover from its contents.
• Induction caused by static electricity without any contact of the material.
Two type of faults and

different circuits
The ESD damages are divided into two groups 65
65
of faults: direct fault and latent defect. The direct
faults are quite easy to detect since the component
will not work at all and this is very often discovered
at the factory before shipping.
The latent defects can be very difficult to
identify since the component is not working in
a reliable way and the life length of the device
may be reduced dramatically.
Fault generated by ESD
Digital circuits:
• ”Ones” becomes ”zeros” and ”zeros”
becomes ”ones” for no reason.
• No ”ones” or ”zeros” at all ( the circuit is dead).
Analogue circuits:
• Worsening accuracy of measuring Printed Circuit Board (PCB)
• Wrong voltage levels that require adjustments

• Malfunction
Electro static voltage levels Protection against ESD
ESD - Electro Static Discharge
A voltage level of between 100-500 V can damages

destroy any electronic components in principle. It is possible to reduce the risk of ESD to a
The most sensitive components can only with- minimum for the equipment. This is very
stand voltages between 25-170 V. important to remember when making service
Sometimes it is possible to hear a ”click” and/or repair with electronic components for
sound when touching an object and that is example the printed circuit board on a softstarter.
typical ESD phenomena. When it is possible to
hear that ”click” sound the voltage level is already Actions to prevent damages:
at least 3,5 kV. Sometimes it is also possible to • Avoid charge if possible
see a spark when touching an object and the
voltage level is then at least 10 kV. • Always use a wrist strap or similar
connected to ground potential when
Below some values are given for typical Electro working with electrical components
static charge: • Always use the right type of package (ESD
Walking on a wall-to-wall carpet: 10 - 20 kV protected bags, etc.)
Walking on a plastic floor (PVC): 2 - 5 kV • Connect all machines and apparatus

to ground potential
Walking on an anti-static floor: 0 - 2 kV
66 • High humidity
Lifting paper from a table: 5 - 35 kV
Rising from a chair: 10 -25 kV
Frequently asked questions (FAQ)
FAQ
Main contactor Advantages of by-pass
Q Is there any requirement to put a main Q What are the advantages of using by-pass?
contactor in series before the softstarter?
A Reduction of power loss. It is also possible
A The softstarter does not require any main to reduce the enclosure size and use a higher
contactor but we recommend the use of one IP-class since air ventilation is not required.
for emergency stop and/or trip of the
overload relay. In some applications an MCCB Power loss
can be used instead of the main contactor.
Q What is the power loss of a softstarter
during a continuous run?
Ambient temperature
Q Can I use a softstarter if the ambient A The values can normally be found in the
temperature is higher than the recommended catalogue. For ABB softstarters the following
value during operation? formula can be used (for example for
PS S 18...300):
A The softstarter can normally be operated PLtot = [3 x Ie x 1.0] + 50 (W) reduced to
at a higher ambient temperature during 50 W only which is the power of the cooling
operation if the rated current for the unit is fans when using by-pass.
derated according to the manufacturer’s Ie is the operational current of the motor.
recommendation. 67
67
Utilisation category
Thyristor shorted
Q What utilisation category should be used for
Q Is it possible to run a softstarter with one the main contactor and the by-pass contactor?
thyristor shorted?
A Main contactor: always use AC-3.
A Yes, it is possible but not for all types of By-pass contactor: it is possible to use AC-1.
softstarters.
Fault indication when starting
Soft stop applications
Q Why does the softstarter indicate a fault
Q What applications are suitable for soft stop? when the start signal is given to the main
contactor and softstarter at the same time?
A Pumps and conveyor belts loaded with fragile
products are the two main applications A If the main contactor is closed too late the
suitable for soft stop. softstarter will indicate this as a phase loss
fault. Delay the start signal to the soft starter
by approx. 0.5 sec. to solve this phenomenon.
Test without motor Different frequency
FAQ
Q Can I test a softstarter without using a motor? Q Can I use the same softstarter at both 50
and 60 Hz?
A No, this is not possible since there will be no
current going through the softstarter and A It is possible with all type of ABB softstarters
some types will also indicate loss of load. as long as the curve is sinusoidal.
Overload relay trips during start Voltage fluctuations

Q Why does the overload relay trip during start? Q What voltage fluctuations are allowed for
the softstarters?
A Possible reasons can be one of these or in a
combination: A The minimum and maximum value where
- too low current limit we can guarantee full function is -15 % to
- too long ramp time +10 % of the rated value. This is also stated
- too low initial voltage in the IEC-standard.
- wrong tripping class on the overload Example: 400 V - 15 % to +10 % ≥ 340 V -
- wrong setting on the overload 440 V range.
Separate overload relay when Semi-conductor fuses

68 using by-pass
Q Do I always have to use semi-conductor fuses?
Q Do I need a separate overload relay when
using a softstarter with built-in electronic A When using semi-conductor fuses a type 2
overload and by-pass? co-ordination can be achieved.
It is possible to use an MCCB (moulded
A If the current transformers of the softstarter case circuit breaker) or MMS (manual
can be installed so that the measuring can motorstarter) instead but then with a type 1
be performed when by-passed a separate co-ordination. For a more in-depth
relay is not required; otherwise yes. description see the chapter on co-ordination.
Environmental information
How a product affects the environment is a matter that is becoming more and more
important when designing new products today but also when updating existing product
ranges. In order to get a complete picture of all environmental aspects, there are some
different methods of doing this.
LCA
LCA (Life Cycle Assessment) is a management
tool for appraising and quantifying the entire
life cycle of particular materials, the impact of
products or activities over their total lifetime by
analysing the entire life cycle of particular
materials, processes, products, technologies,
services or activities. The most important aspects
affecting the environment for a softstarter has 69
proven to be:
• Choice of material in the softstarter

• Energy losses during lifetime
• Recycling possibilities The LCA process includes the
entire lifecycle of a product
EPD and losses. It is possible to see the difference
when using the softstarter In-line, Inside Delta

EPD (Environmental Product Declaration) is a and/or with a by-pass contactor.
document describing the environmental effects
both during manufacturing and the usage of a Tables for global warming potential, ozone
specific product, for example the softstarter range depletion potential, acidification potential and
PS S 18/30...300/515. The document includes so on are also included. The complete declaration
among other things a material list indicating is available on www.abb.com under document
kg/product used of aluminium, copper, steel, number 1SFC 288007-en.
glass, etc. and also tables for energy consumption
Type of material kg/product kg/kW

Aluminium 2.2 0.03
Cardboard 2.4 0.03
70 Copper and copper alloys 3.1 0.04
Steel 4 0.05
Wood 0.83 0.01
Polymers 1.7 0.02
Epoxy resin 0.033 0.000
Glass 0.025 0.0003
Silicone rubber 0.0047 0.9*10-4
Example of a material list for a softstarter.
Industrial IT
Industrial IT
ABB has committed, as a key element of its business strategy, to a broad program of
product development and positioning under the Industrial IT umbrella (IIT). The
main reason behind the Industrial IT certification is to make it easier and more
effective to combine products into systems and solutions.
All products that pass the Industrial IT certification tests achieve the Industrial IT
enabled sign.
Enabled products are verified for properties that make them work together in a pre-defined manner
with other enabled products in an Industrial IT environment throughout the full life cycle of the
plant. This means that IIT certified products should be easier to:
• Purchase
• Design
• Engineer
• Install
• Commission
• Operate
• Maintain 71
• De-install
Different levels
Industrial IT
In order to acknowledge the fact that there are different requirements on integration
properties between different applications and markets, there are four levels that a
certain product can be certified for:
Level 0 - Information Level 3 - Optimisation

• Product is supplied with minimal aspect set • As Integration, plus.
in prescribed formats including Product
• Aspect Object Types are provided with
Information, Product Classification,
at least the Extended set of Aspects.
Product Documentation, CAD Data and
Technical Data. • Relevant functionality is available as
Aspect Systems on integration level 3.
Level 1 - Connectivity • The product is handled consistently
• As Information, plus. throughout the life cycle and value chain.
• Hardware can be physically connected Softstarter level

72 via defined interfaces.
All our softstarter ranges today are Industrial
• Software is installed and handled in a
IT enabled with the suite name Control IT
consistent way.
Softstarters, certifiaction level 0 - Information.
• Basic interoperability of the product in An Industrial IT enabled product can be
the environment it is inserted in. recognized by the Industrial IT enabled sign on
the packing.
• Basic data can be exchanged via defined
More information and documentation is
protocols.
available on www.abb.com
Level 2 - Integration
• As Connectivity, plus.
• Aspect Object Types are provided with
at least the Basic set of Aspects.
• Extended data can be exchanged via
defined protocols.
• Relevant functionality is available as
Aspect Systems on integration level 2.
Formula and conversion factors

In this chapter some useful formula and conversion factors can be found.
The formulas can be used for calculating for example rated motor torque, moment
of inertia, flywheel mass, etc.
The conversion factors can be used to convert for example kW to HP, Celsius to
Fahrenheit, km/h to miles/hour, etc.
Formula
Ohm’s law
I=U R=U U=IxR I = Current (ampere)
R I
U = Voltage (volt)
R = Resistance (ohm)
Rated motor torque
Mr = 9550 x Pr Mr = Rated torque, Nm
n
r Pr = Rated motor power, kW
nr = Rated motor speed, rpm 73
Moment of inertia
2 2 2
J = m(R + r ) J = Moment of inertia, kgm
2 m = Mass for the flywheel, kg
R = Outer radius, m
r = Inner radius, m
Flywheel mass
mD2 or GD2 (mD2 ~ GD2) mD2 = Flywheel mass, kpm2
GD2 = Flywheel mass, kgm2
Relation Moment of inertia and

Flywheel mass
2
J = 1 GD = 1 mD
2 J = Moment of inertia, kgm2
4 4 mD2 = Flywheel mass, kpm2
GD2 = Flywheel mass, kgm2
Moment of inertia on load shaft

recalculated to the motor shaft
J x nb2 J´b = Moment of inertia recalcu lated
J´b = b
n to the motor shaft, kgm2
Jb = Moment of inertia for the load,
kgm2
nb = Speed of the load, rpm
nr = Speed of the motor, rpm
Load torque on load shaft
recalculated to the motor shaft
Mb x nb M´b = Load torque recalculated to
M´b =
nr
the motor shaft, Nm
Mb = Load torque, Nm
74 nb = Speed of the load, rpm
nr = Speed of the motor, rpm
Electrical power
U x I x PF P = Power in kW (1-phase)
P=
1000 PF = Power factor
U x I x PF x √2 P = Power in kW (2-phase)
P=
1000
U x I x PF x √3 P = Power in kW (3-phase)
P=
1000
Quantities and units Power / Energy
HP = horsepower
Length
W = watt
yd. = yard
kW = kilowatt
m = metre
kWh = kilowatt-hours
mm = millimetre
cm = centimetre Volume
in. = inch l = litre
ft. = feet ml = millilitre
km = kilometre cu.in. = cubic inch
cu.ft. = cubic feet
Time
gal. = gallon
h = hour
fl.oz. = fluid ounce
min = minute
s = second Electrical
A = Ampere
Weight
V = Volt
oz. = ounce 75
W = Watt
lb. = pound
Ω = Ohm
kg = kilogram
F = Farad
g = gram
Conversion factors
Length
1 mile = 1,609344 km 1 km = 0,621 mile
1 yd = 0,9144 m 1m = 1,09 yd
1 ft = 0,3048 m 1m = 3,28 ft
1 in = 25,4 mm 1 mm = 0,039 in
Velocity
1 knot = 1,852 km/h 1 km/h = 0,540 knot
1 mile/h = 1,61 km/h 1 km/h = 0,622 mile/h
1 m/s = 3,6 km/h 1 km/h = 0,278 m/s
Area
1 acre = 0,405 ha 1 ha = 2,471 acre
1 ft2 = 0,0929 m2 1 m2 = 10,8 ft2
1 in2 = 6,45 cm2 1 cm2 = 0,155 in2
76
Volume
1 ft3 = 0,0283 m3 1 m3 = 35,3 ft3
1 in3 = 16,4 cm3 1 cm3 = 0,0610 in3
1 gallon = 4,55 l (UK) 1l = 0,220 gallon (UK)
1 gallon = 3,79 l (US) 1l = 0,264 gallon (US)
1 pint = 0,568 l 1l = 1,76 pint
Mass
1 lb = 0,454 kg 1 kg = 2,20 lb
1 oz = 28,3 g 1g = 0,0352 oz
Moment of Inertia
1 Nm2 = 2,42 ft.-lb2 1 ft.-lb2 = 0,41322 Nm2
1 kgm2 = 0,2469 ft.-lb2 1 ft.-lb2 = 4,0537 kgm2
1 oz.-in2 = 0,000434 ft.-lb2 1 ft.-lb2 = 2304,147 oz.-in2
Force
1 kp = 9,80665 N 1N = 0,102 kp
1 lbf = 4,45 N 1N = 0,225 lbf
Energy
1 kpm = 9,80665 J 1J = 0,102 kpm
1 cal = 4,1868 J 1J = 0,239 cal
1 kWh = 3,6 MJ 1 MJ = 0,278 kWh
Power
1 hp = 0,736 kW 1 kW = 1,36 hp
1 hp = 0,746 kW (UK,US) 1 kW = 1,34 hp (UK;US)
1 kcal/h = 1,16 W 1W = 0,860 kcal/h 77
Temperature
0 oC = 32 oF
oC = 5 / 9 (oF-32)
0 oF = -17,8 oC
oF = 9 / 5 (oC+32)
Glossary
AC Alternating current.
Glossary
Ambient Temperature Ambient temperature is the temperature of water,

air or surrounding medium where the equipment is
used or stored.
Asynchronous speed The speed of an AC induction motor at full load

and full voltage, also defined as the rated speed.
Bearing A component used to reduce the friction and wear

between rotating devices.
By-pass A by-pass contactor is used to by-pass another device,

for example a softstarter to reduce the power loss.
CSA Canadian Standard Association
Current limit An electronic method to limit the starting current

to the motor during start up. It is normally possible
to adjust the function so that the motor torque will
be high enought to take off.
78
Cycle A sequence of operations that is repeated regularly
or the time it takes to complete one operation.
D-end The end that is normally the drive end of an electrical

motor.
DC Direct current
Degree of Protection Defined and stated as IP (International Protection)

class indicating the degree of protection against
contact and penetration of solid objects and water.
Derating When a device has to be operated with reduced

ratings (normally the current) due to high ambient
temperature or high altitude.
D.O.L Direct-on-line
Glossary
Duty Cycle The total cycle from one start to the next, including
ramp time for start and stop, operation and pause
time, if any.
Efficiency The ratio between mechanical output and electrical

input. The percentage given indicates how effective
the motor is at converting electrical energy to
mechanical energy.
EMF Electromotive Force, another term for voltage or

potential difference, for example the voltage generated
by a motor.
EPD Environmental Product Declaration, a description

of how a specific product affects the environment.
ESD Electro Static Discharge.
Fault Any malfunction that occur and interferes with normal

operation.
Flywheel mass The total mass (mD2 or GD2) of a rotating body 79

normally given in kpm2 or kgm2. The value of the
flywheel mass is 4 times the moment of inertia.
Frequency The number of periodic cycles per unit of time.
Gate The control element of an SCR (thyristor).

When giving a small positive voltage to the SCR it
will start conducting.
Heat Sink A component often made of aluminium used to get

rid of the heat inside an electrical device generated
by the current.
Heavy Duty Start A start with a load that has a high or very high moment
of inertia. A starting time D.O.L. of more then 5
seconds can be defined as a heavy-duty start.
High load torque The braking torque on the motor shaft caused by
Glossary
the load. If the braking torque is equal or nearly

equal to the rated motor torque it can be defined as
high load torque.
IEC International Electrotechnical Commission which

is part of the International Standard Organisation.
Inertia A measure of a body’s resistance to change in velocity

whether the body is moving at a constant speed or
is at rest. The velocity can be rotational or linear.
Induction motor An AC motor with a primary winding (usually the

stator) connected to the power supply and a secondary
winding (usually the rotor) carrying the induced
current.
In-Line connection A connection type where the devices in the main

supply are connected in series with each other.
Inside Delta connection A connection type where the devices are connected
80
inside the motor delta circuit. The current is reduced
to 1/√3 = 58% compared to the line current.
Integrated Circuit (IC) A small electronic unit that can consist of thousands
of transistors usually mounted on a PCB.
Intermitens factor The relation between how long a machinery is

working (ON time) and how long it is resting
(OFF time) in a cycle.
Jog Momentary moving of the motor by repetitive closure

of a circuit using a contact element or a pushbutton.
LCA Life Cycle Assessment, an analysis of how a product

affects the environment from ”cradle to grave”.
Glossary
LCD Liquid Crystal Display, a readout interface used in
digital watches and laptop computers.
LED Light-emitting diode.
Locked Rotor Current The current taken from the line when a rotor is at
a standstill at rated voltage and frequency.
It is the on line current when starting the motor direct.
Megger Test This is normally measured in megohms using full

voltage with low current and is used to measure the
resistance in an insulation system.
It can be used for checking the thyristors, for example.
Micro processor A central processing unit utilising large-scale

integration technology.
MCCB Moulded Case Circuit Breaker
MMS Manual Motor Starter
N-end The end that is normally the non-drive end of an 81

electrical motor.
NEMA The National Electrical Manufacturers Association

(USA)
Network A number of nodes connected to each other with

some type of communication medium. A network
can be of single link type or multiple link type.
Noise Unwanted disturbances in a communication medium

that tend to obscure the data content.
Normally Closed Contact A contact or set of contacts that are closed when
(NC) the relay or switch is de-energised. The contact(s)
open when a relay or switch is energised.
Normally Open Contact A contact or set of contacts that are open when
Glossary
(NO) the relay or switch is de-energised. The contact(s)

close when the relay or switch is energised.
Normal Start A start with a load that has small or medium high
moment of inertia. A starting time D.O.L. of less
then 5 seconds can be defined as normal start.
Overload relay A device used to avoid overheating of the motor.

Can be of electronic or thermal type.
Parallel start Parallel start of motors is normally when two or more

motors are started at the same time with the same
starting equipment.
PCB Printed Circuit Board.
PLC Programmable Logic Controller, consists of a central

processor, input/output interfaces and a memory
designed as an industrial control system. A PLC
system is used for the storage of instructions, timing,
82
counting, report generation I/O control and more.
Power Work done per unit of time measured in horsepower

(HP) or watt (W).
Power Factor The phase difference measured between the voltage

and the current in an AC circuit represented by the
cosine angle.
Protocol A set of conventions governing the format and timing

of data between communication devices.
Reversing Changing of the rotation direction of the rotor or

motor armature.
SCR Silicon Controlled Rectifier often referred to as a

thyristor.
Glossary
Semi-conductor fuses A special type of high-speed fuse used as thyristor
protection since normal (gG/gL or aM) fuses are not
fast enough.
Sequential start Sequential start of motors is normally when two or

more motors are started one by one in a sequence
with the same starting equipment.
Serial Communication The way of transmitting data in a network

between different nodes, using some type of
protocol.
Slip The difference (usually expressed in percentage)

between the synchronous speed and the rotor speed
of an AC induction motor.
Star connection The connection type where each winding in a polyphase

circuit is connected at one end to a common point.
Synchronous speed The speed of the rotating magnetic field on an AC

induction motor determined by the frequency and
83
the number of magnetic poles in each phase of the
stator windings.
Thyristor A solid-state switch that has an anode, cathode and

a control element called the gate, which makes it
possible to turn it on at will. It can rapidly switch
large currents at high voltages.
Tripping class The tripping class defines the starting time at a

specific current before tripping occurs.
Different classes exist, for example 10, 20, 30 etc.
where class 30 allows the longest starting time.
Torque A measure of the turning force ability for a device.
UL Underwrites Laboratories (an approval agency).
Y connection See Star connection.

Index
A
Index
F
Accelerating torque 15 Fan 35
Adjustable rated motor current 38 Suitable softstarter 18
Ambient temperature 41 FAQ - Softstarters 67
Fault 39
B Firing angle 35
Braking load torque 15 Formula and conversion factors 73
Frequency drive 12
C
Fuses 61, 64
CE Marking 1
Centrifugal fan. See Fan G
Centrifugal pump. See Pump Glossary 78
Co-ordination 58, 59
table of 62, 63 H
Common problems, table of 14 Harmonics 55
Compressor 23 Heat sink 35
Suitable softstarter 26 High altitudes, derating 42
84 Control voltage 40 Housing 35
Conveyor belt 27
Suitable softstarter 30 I
CSA specifications 1 In-line connection 46
Current limit 37 Indications 39
Industrial IT 71, 72
D Levels of certification 72
D-end 2 Initial voltage 36
Delta connection 4 Inside delta connection 46
Direct-on-line start 9, 16, 19, 23, 27
L
E Life Cycle Assessment (LCA) 69
Electro Static Discharge(ESD) 65, 66
Electronic overload relay (EOL) 33
Environmental Product Declaration
(EPD) 70
Explosive atmospheres (Ex) 56
Zone catergories 57
M Start ramp 36
Index
Step down voltage 38
Main voltage 40
table, with current lim. 51
Motors
table, without current lim. 50
about 2
settings
calculations, speed 6
Stop ramp 36
calculations, torque 7
Softstarter 13, 17, 21, 25, 29
mechanical overview 2
Component picture 34
Parallel start 43
How to select - Quickguide 31
problems, start & stop 14
Indications 39
Sequential start 44
Starting capacity 52
Slip-ring 7
starts/hour 54
Squirrel cage 3
using by-pass contactor 53
Winding 4
using overload protection 53
O Standards 1
Overload 39 Star-delta start 10
Overload relay. See Electronic Star-delta starter 17, 20, 24, 28
Start connection 4
overload relay (EOL) 85
Start ramp 36
P Starting capacity 52, 53
Power factor 5 Step down voltage 38
Printed Circuit Board (PCB) 35 Stop ramp 36
Pump 19 Supply voltage 40
stopping a pump 20 T
Suitable softstarter 22
Temperature, derating 41
Q Thyristor 35
Quick guide, softstarter applications U
31
UL specifications 1
S Utilization Categories 60
Settings 36 V
Adjustable rated motor current 38
Current limit 37 Voltage 4
Initial voltage 36 Voltage definitions 40
86
ABB Automation Technologies AB/Cewe-Control, SE-721 61 Västerås, Sweden, Telephone +46 21 32 07 00, Telefax +46 21 12 60 01
Id.No 1SFC132002M0201, ed. 2, September 2004, ATAP/CL/XM, reprinted in Sept.2004/Edita Västra Aros

Soft Starter Handbook

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SOFTSTARTER

ABB Automation Technology Products AB, Control

Magnus Kjellberg Sören Kling

General about motors ...2

Different starting methods ...8

Different applications ...15

Direct-on-line start (D.O.L) ...23

How to select a softstarter ...31

Different voltage names ...40

Basic settings ...49

Starting capacity and overload protection ...52

Number of starts/hour ...54

Harmonics ...55 III

Explosive atmospheres (EEx) ...56

ESD aspects ...65

Environmental information ...69

Formulas and conversion factors ...73

European Directives Specifications in USA and

motors, three-phase motors, brake motors, synchronous motors, asynchronous motors,

Note that in this handbook we will focus on asynchronous motors only.

Stator windings Stator

I Max. starting current Max. torque

Rated current Rated torque

the main voltage is 400 V, the Y-connection is

Diagram indicating P, Q, S and Cos ϕ

asynchronous speed also named rated speed is

n = 2 x 50 x 60 = 1500 rpm 6 1000 1200

squirrel cage motors.

Direct-on-line start (D.O.L) Frequency converter

Start-delta start Softstarter

I Max. starting current

Star-delta start accelerate the motor up to speed before switching

Torque/speed curve at Star-Delta start Current curve at Star-Delta start

Frequency converter fact that there is no need for speed regulation

Common problems when starting and stopping motors with

Type of problem Type of starting method

High inrush current Yes No No No

Heavy wear and tear Yes Yes No No

Damaged goods / Yes Yes No No

Water hammering in pipe Yes Yes Best Reduced

Transmission peaks Yes Yes No No

Direct-on-line start The belts slip depending on whether the starting

Torque/speed curve at D.O.L start Current curve at D.O.L start

Torque/speed curve at Star-Delta start Torque/speed curve when using a softstarter

Application with a centrifugal fan

Torque/speed curve at D.O.L start Current curve at D.O.L start

Star-delta starter (Y-D) When stopping a pump

Application with a pump.

Star-delta starter (Y-D) will occur with high mechanical stresses as a

Application with a compressor

Low braking torque High braking torque

Low braking torque High braking torque

Low braking torque High braking torque

Application with a conveyor belt

How to select a softstarter

If more than 6 starts /h

Description of the softstarter

Printed circuit board

Off : Thyristor is non-conducting