Contents Standards and approvals 1 Definitions, different voltages About motors Squirrel cage motors Speed Voltage Current Power factor Torque Slipring motors Different load conditions 10 Different starting methods 12 Direct on line (DOL) 13 Star-delta starter 14 Frequency converter 16 Softstarter 18 Comparision between different starting methods 20 General about softstarters 24 Softstarter functionality 22 Torque control 24 Different applications 26 Centrifugal fan 27 Centrifugal pump 29 Compressor 32 Conveyor belt 34 Crusher and Mill 37 Softstarter Handbook 1SFC132060M0201 | IContents How to select a softstarter for different applications Ambient temperature Derating when used at high altitudes Starting capacity and overload protection Number of starts per hour Prosoft Different ways of connecting the softstarter Start of several motors Connection of control circuit Connecting a softstarter to a fieldbus system 2-phase control vs 3-phase control Settings Explosive atmospheres Coordination Environmental information Harmonics FAQ (Frequently asked questions) Quantities and units Formulas and conversion factors Glossary Index 1V | Softstarter Handbook 1SFC132060M0201 89 40 Ad 42 44 1 45 46 1 4B .. 50 51 .. 52 54 .. 58 .. 60 .. 67 .. 68 . 69 71 72 . 16 83Standards and approvals CEG) Os All ABB low voltage softstarters are developed and manufactured according to the rules set out in the IEC (International Electrotechnical Commission). The IEC issue publications that act as a basis for the world market, The IEC standard for softstarters is called IEC 60947-4-2 and softstarters built according to this standard are in most countries not subject to any other tests besides the manufacturer responsibility. In some countries, law requires certificates. European Directives There are three essential European direc- tives: Low Voltage Directive 206/95/EC Concerns electrical equipment from 50 to 1000 V AC and from 75 to 1500 V DC. Machines Directive 2006/42/EC Concerns safety specifications of ma- chines and equipment on complete ma- chines Electromagnetic Compatibility Directive 2004/108/EC Concerns all devices able to create elec- tro-magnetic disturbance including the level of emission and immunity. CE Marking When a product is verified according to its applicable EN standard, the product is presumed to fulfll both the "Low Voltage Directive” and "Electromagnetic Compa- bility Directive” and it is allowed to use the CE marking on the product. EN 60947-4- 2 is the harmonized standard for softstart- ers and it is identical to IEC 60947-4-2. In this case, the CE marking does not cover the "Machines Directive” which will require a special verification of the instal- lation of the machine. Since a softstarter is an electrical device, with mainly electrical risks, it is instead covered by the low volt- age directive. The CE marking is not a quality label; it is proof of conformity with the European Directives concerning the product. Softstarter Handbook 1SFC132060M0201 | 1Standards Specifications in USA and Canada The specifications for the American and Canadian markets are quite similar, but differ a lot from the IEC standards and Eu- ropean specifications, USA - UL Underwriters Laboratories Inc. Canada - CSA Canadian Standards As- sociation There are different types of UL certifica~ tion, among them UL listed and UL com- ponent recognition. UL listing means that UL has tested representative samples of the product and determined that it meets UL's requirements. UL's component rec- cognition service, however, only covers the evaluation of components or materials in- tended for use in a complete product or system. All ABB softstarters that have UL certification, are UL listed Softstarters can also be cULus listed, meaning that they are UL listed to US and Canadian safety standards. All the require ments of both UL and CSA are covered by cULus, so the product is then suitable for use in the US and in Canada. CCC (China Compulsory Certification) Since the softstarter standard is listed ac- cording to the CCC-regulation in China, it is mandatory to have the product ap- proved and labelled with a CCC-mark to be allowed to be put on the Chinese mar- ket. The Chinese GB14048.6-2008 stan- dard is based on the IEC-standard IEC 60947-4-2. 2 | Softstarter Handbook 1SFC132060M0201 ®@. € © 0 @ Other local approvals based on IEC-standard In addition to IEC and UL standards, many countries have their own local standards. Some of the major ones besides the already mentioned CSA and CCC are listed below: GOST - Russia C-tick — Australia ANCE - Mexico Marine approvals For softstarters used on board ships, mari- time insurance companies sometime require different marine certificates of approvals These can come from BV (Bureau Veritas), GL (Germanisher Lloyd), LR (Lloya’s Reg- ister EMEA) which are based on the IEC standard, or from ABS (American Bureau of Shipping) which is based on the UL stan- dard or from some other independent cer- tification organisation. Normally, marine ap- provals have special requirements regarding shock, vibrations and humidity. Used standards Following standards are used or partly used for the softstarters. IEC 60947-1 EN 60947-1 IEC 60947-4-2 EN 60947-4-2 UL 508 CSA C22.2 No. 14 GB14048,6-2008 LR Test specification No. 1Definitions, different voltages Different named voltages are used for the softstarters. The name and use of these different voltages is stated in the IEC-standard (IEC 60947-1) as below. Operational voltage (Ug), is the voltage feeding the motor and also the voltage exposed to the main circuit (thyristors) in the softstarter. 200 -690V AC are normal values. Control supply voltage (U,), is the voltage feeding the electronic com- ponents inside the softstarter, for example the printed circuit board. A common volt- age is 100 - 250 V AC. Operational voltage (Ue) intemal control circuit voltage L112 13 Start Power Control supply Stop __ supply — voltage (Us) 71-12 13 Softstrter with internal contol cuit voltage Control circuit voltage (Ug), is the voltage for controling the start and stop command of the softstarter. Common values are 24 V DC or 110 - 240 V AGC. On many softstarters, the control voltage can be supplied internally. Operational voltage (Ue) || L1L2 13 External Power tro! Snel art Conta Sieut step supp fotage (Ue) ipply voltage (Us) T1712 73: starter with external control crcult voltage Softstarter Handbook 1SFC132060M0201 | 3About Motors Modern electrical motors are available in many different forms, such as single phase motors, three-phase motors, brake motors, synchronous motors, asyn- chronous 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 ex- ample 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 life for the motor it is important to select it with the correct degree of protection when operating under heavy-duty conditions in a severe 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 pen- etration of solid objects, whereas the second states the motor's degree of protection against water. The end of the motor is defined in the |EC-standard as follows: * The D-end is normally the drive end of the motor. The N-end is normally the non-drive end of the motor. Note that in this handbook we will focus on asynchronous 3-phase electrical motors only. Terminal box Cooling fan Drive shaft ™ D-end N-end Stator Stator windings 4 | Softstarter Handbook 1SFC132060M0201