Soft Starters
Why soft starters?
Reactor based soft starters by reducing the heating caused by frequent start/stops, reducing the mechanical stress on the motor and its shaft, and reducing the electro dynamic stresses on the power cables, soft starters will protect your electric motor from possible damage while also extending the lifespan of your electric motor and the entire system.
- Thyristor damage.
- When starter overheated, the fault light is on and the soft starter stops working.
- The soft starter has a repeated start.
- During the starting process, the current is unstable.
- The soft starter stops working and the motor coasts to a stop.
Are you facing same problems with existing motor starting solution? Wants modern FCMAplus based soft starter? then stop searching you are on your destination.
iEngineering group can provide one of the best customize motors starting Solutions. We can supply L.T & H.T Soft Starters which are FCMAplus technology based and complying with AS/NZS 60076-6 standard. We have LT & HT FCMA type, reactor based Soft Starters up to 20 MV, 13.8 kV, and 50/60 HZ. We serve all major industries like Water treatment & water supply, Steel plants, Infrastructure & HVAC, Pharmacy industries, oil & gas, Fertilizers, Automobiles, Textiles, Paper mills.
Difference between Electronic soft starter and FCMAPlus/HFSRPlus soft starter
| Sr. No. | Parameters | Electronic Soft Starter | FCMAPlus/HFSRPlus Soft starter |
|---|---|---|---|
| 1 | Operation Principle of | Using Thyristor / IGBT/MOSFET Control; power electronic device will cut the sine wave disturbing the fundamental frequency of the sine wave. | Reduced Voltage by potential divider action. Motor voltage increases gradually with speed up to 95%. Final bypass to full voltage. Only Amplitude control, so no harmonics. |
| 2 | Starting Current | Starting current is higher in the range of 3.5 - 4 times the full load current, and cannot achieve a lower starting current of 1-1.5 times the full load current | Starting current is reduced to the minimum theoretical value as no current is wasted in harmonics. The entire current is at fundamental frequency. With the offered FCMAPlus/HFSRPlus soft starting solution, the starting current can be reduced to 1 - 1.5Ifl. |
| 3 | Harmonics | Since the fundamental sine wave is disturbed, harmonics are generated, polluting the power system and damaging capacitors, Increased heating in motors etc. | FCMAPLUS/HFSRPlus are entirely Harmonics Free systems. |
| 4 | Maintenance | Electronics Technology obsolescence after 3-4 years. Spares are imported and costly mostly not available due to obsolescence. Hence heavy expenditure for the replacement. | No obsolescence. Simple and rugged system. No routine maintenance required. |
| 5 | Operation and Reliability | Power electronics components are prone to failure. Requires controlled cooling environment, thereby increasing the capital and running cost of the equipment. | Ensures high reliability. Can operate in the harsh environment; up to 50°C ambient temperatures, without any need of cooling. |
| 6 | Cost | Electronic soft starters are more cost effective in LV range. | Our reactor based soft starters are more competitive in HT range (3.3kV, 6.6kV and 11kV range). Installation cost is smaller than 10-15% than electronic soft starter. |
Low Voltage FCMAplus soft starter
Our LV FCMAplus soft starters are air-core based series reactors, providing a complete starting solution for any motor application involving pumps, blowers, fans or compressors. We design customized solutions specific to each motor, analysing motor and load torque speed curves, current speed and moment of inertia.
Soft starters are provided with a bypass device (power contactor or air circuit breaker) of customer preferred make. When required by the customer, we offer a complete solution with motor feeder i.e. ACB /power contactor with MPR and metering for switching and protection purpose. All our starters are automated using a PLC with HMI which creates reliability.
The standard starting current committed by our soft starters is 3-3.5 times the full load current. We can also reduce the starting current up to 1 to 1.5 times the full load current if required by using a Dynamic Compensator.
Our LV soft starters offer the best competitive value for our customers and offer superior value than the conventional electronic soft starters.
| Technical specification | ||
|---|---|---|
| Input Voltage | 415V/690V | |
| Motor Power Range | Up to 2,000 kW | |
| Application | Pump, Compressor, Fan, Blower | |
| Frequency | 50Hz/60Hz | |
| Temperature Operation Range | 0°C to 55°C | |
| Installation | Indoor | |
| Cooling Method | Air Cooled | |
| Insulation Class | Class F or customized | |
| Standard | IEC 60076-6 | |
| Construction | Air Core, Vacuum Pressure Epoxy Impregnated | |
| Conductor | Electrolytic Copper | |
| Starting Current | Version 1: 3-3.5 times starting current Version 2: 1.5 times full load current with Dynamic Compensator | |
| Reactor variation | 5-tap design at 5% voltage difference at each tap | |
Medium Voltage FCMAplus soft starter
Our MV FCMAplus soft starters are air-core based series reactors, providing a complete starting solution for any motor application involving pumps, blowers, fans or compressors. We design customized solutions specific to each motor, analysing motor and load torque speed curves, current speed and moment of inertia.
Starting current will be reduced 3 to 3.5 x full load current (IFL) typically for any applications like pump, compressor, fans, blowers, mills. A standard product will be provided with the FCMAplus/HFSR soft starter with bypass vacuum contactor of customer preferred make or with a bypass vacuum circuit breaker. Our line-side soft starters are designed for fault level of the system. We use closed loop control using a PLC Line side soft starter are preferred for motors in hazardous area or when neutral terminal box is not available.
We use closed-loop control using a PLC Line side soft starter is preferred for motors in hazardous areas or when the neutral terminal box is not available.
| Technical specification | ||
|---|---|---|
| Input Voltage | 3.3 kV to 13.8 kV | |
| Motor Power Range | 200 kW to 20MW | |
| Application | Pump, Compressor, Fan, Blower | |
| Frequency | 50Hz/60Hz | |
| Temperature Operation Range | 0°C to 55°C | |
| Installation | Indoor | |
| Cooling Method | Air Cooled | |
| Insulation Class | Class F or customized | |
| Standard | IEC 60076-6 | |
| Construction | Air Core, Vacuum Pressure Epoxy Impregnated | |
| Conductor | Electrolytic Copper | |
| Starting Current | Compensator Version 2: 1.5 times full load current with Dynamic Version 1: 3-3.5 times of full load current | |
| Reactor variation | 5-tap design at 5% voltage difference at each tap | |
The standard starting current committed by our soft starters is 3-3.5 times the starting current. We can also reduce the starting current up to 1 to 1.5 times the starting current if required by using a Dynamic Compensator.
Our MV soft starters offer the best competitive value for our customers and offer superior value than the conventional electronic soft starters.
Product Features
- We use VPI with a unique epoxy resin material to get high mechanical and insulating strength.
- High margin is considered in electrical and thermal design for extended lifetime.
- Inductance tolerance & design as per AS/NZS 60076/6.
- Maintenance free & environment friendly reactor.
- Power system engineering to offer customized solutions.
Why iEngineering Soft starter?
| FCMAPlus/HFSRPlus Soft starter | Other Soft Starter Manufacturers |
|---|---|
| Our VPI technology, unique amongst our competitors, allows for greater rigidity to our coils, to ensure each turn, layer and interstice is impregnated with resin, allowing for unmatched rigidity and insulation integrity. This indispensable feature allows for greater longevity of our soft starter’s vis-à-vis our competitors. | No VPI technology presents; results in poor rigidity of coils and lower longevity of starters. |
| We separate ourselves from the competition by measuring the impedance of the reactor coils which guarantees the starting current of the motor as promised to the customer. We follow strict quality norms outlined in AS/NZS 60076-6, IEC-60076-6, ensuring the customer receives accurate impedance measurement. | No measurement of Impedance; will result in inexact starting current as it is critical to accurate starting current prediction. |
| We offer versatile design with FIVE different voltage tap designs - Design Tap (DT) (DT +5%, DT +10%, DT +15%, and DT +20), as per AS 60034 IEC-60034 for starting current and starting torque, motor starter manufacturers specify design tolerance of 20% for starting current and torque. To have flexibility in accommodating variations in motor and driven equipment due to operating conditions, the tolerance is highly essential. | Our competitors offer a 3-tap design or a single tap design, thus offering an inferior flexibility when it comes to starting current selection of the motor. This results high bypass current. |
Case Studies:-
- Shovel application for coal mines: –
Motor rating – 560KW, 6.6KV, 59Amps
Motor started with reactor based Soft starter – 100Amps
Panel customized to fit in the available space inside the shovel (Vehicle)
Starting current limited to 1.5 I_fl
Iron and Steel Company:
Transformer MVA: -11MVA, 11KV
Internal impedance: – 8%
Motor details -: 3.2MW, 11KV.
Base load – 225KW (Aux LT loads)
| SI. No | Model of Soft starter | Starting current Seen by the Power System (A) | Base Load in KW on Transformer before starting | % Voltage drop | Motor starting(kVA) | % Over loading of 11 MVA transformer |
|---|---|---|---|---|---|---|
| 1 | DOL starting | 6.5 | 225 | 19.43 | 24821 | 226% |
| | ||||||
| | Starting with SS and support of PF correction of 2000KVAr | 2.75 | 3450 ( 1 motor running with other base load 225KW) | 7.2 | 10437 | No Over loading |
3. Oil Exploration Site Captive Power Plant
Generator: – 10MVA, 0.8 PF since two generators are in parallel
Gen KW = 10*0.8 = 8 MW.
Gen KVAR = 10*0.6*1.4 = 8.4 MVAR, considering an overload of 40 % in reactive power.
Reciprocating Inlet Compressor motor
Compressor Rating 1: 1885 kW, 6600 V, 197.8 a full load current; DOL current: 650%.
Overhead Screw Compressor
Compressor Rating 2: 1350 kW, 6600V, 138.1A full load current; DOL current: 650%.
| Site results of starting | ||||||
|---|---|---|---|---|---|---|
| SI. No | Model of Soft starter | Application | Starting current Seen by the Power System (A) | % Voltage drop | Acceleration time | Generator Capacity |
| 1 | 1350- 2 Step SS with DC | Overhead compressor- SCREW COMPRESSOR | <2.5 Ifl | <2% | 9 sec | 2X5MW GTG |
| 2 | 1885 2 Step SS with DC | Reciprocating compressor-Nitrogen feed gas | <2.5lfl | <2% | 8Sec | 2X5MW GTG |
4. IRRIGATION PUMP: –
Transformer: – 31.5 MVA, 220KV/11KV, 10.5%
Motor: – 10.5 MW, 11KV, 562A, Synchronous
Application: – Pump
| Starting Performance | |||
|---|---|---|---|
| Parameter | DOL | Commitment | At site |
| Ist | 4.2 p.u, | 3.0 p.u. (1686 A) | 2.74 p.u. (1540 A) |
| Tst | 2-3 sec | 12- 13 sec | 10-11 sec |
| V drop | 15% | <10% | 9% |
| Starting kVA | 44,970 KVA | 32,000 KVA | 29,340 KVA |
| Xmer Loading | 1.43 p,u, | 1 p,u, | 0.93 p,u, |
5. Steel plant blower
Motor Details: Frame – YKS-800-4 Motor – 4550 KW, 6600V, 1493 rpm .
Blower: – Flow rate 1330 m3/min, For Sinter plant.
Power Transformer: – 20 MVA with int imp – 10.3%
FCMA-Soft starter Model No: – FCMA- N-4500-6.6KV-40KA1-01-HD.
| Starting Performance | |||
|---|---|---|---|
| Parameter | Commitment | At site | |
| Ist | 3.5xIFL( 889A), | 3xIFL( 762 A) | |
| Tst | 45 Sec | 34 sec | |
| V drop | Less than 1100 Volts (10%), | Actual 750 Volts (6.38%) | |
6. Steel plant
Soft Starter is based on Series reactor principle as per IS5553 Part-3/IEC60289 (old standard), IEC60076-6.
Motor: – 4200KW, 11KV, 50Hz, 1500rpm, Full.
Load current: – 254 Amps.
Application: – Waste gas Fan.
Grid Capacity: – Starting Current: – Committed – 3.5x I-FL (889A), Actual 3xIFL (762 A)
Voltage drop: – Committed – less than 1100 Volts (10%), Actual 750 Volts (6.38%)
Starting Time: – Committed – 45 Sec, Actual – 34 sec.
7. Steel plant– Blower
Motor Details: – Frame – YKS-800-4 Motor – 4550 KW, 6600V, 1493 rpm.
Blower: – Flow rate 1330 m3/min, For Sinter plant.
Power Transformer: – 20 MVA with int imp – 10.3%
FCMA-Soft starter Model No: FCMA- N-4500-6.6KV-40KA1-01-HD.
Performance Figures: –
Starting Current: – Committed by LEPL – 1602 amp, 3.6 I_fl
Achieved by us: – 1456 amp, 3.27 I_fl
Acceleration Time: – 45 Sec.
Volt drop: – less than 5 %
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