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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 the starter overheats, the fault light turns 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
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 - 1.5 fl.
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 replacement.
No obsolescence. Simple and rugged system. No routine maintenance required.
5
Operation and Reliability
Power electronics components are prone to failure. Requires a controlled cooling environment,
thereby increasing the capital and running cost of the equipment.
Ensures high reliability. Can operate in harsh environments; up to 50°C ambient temperatures,
without any need for cooling.
6
Cost
Electronic soft starters are more cost-effective in the LV range.
Our reactor-based soft starters are more competitive in the HT range (3.3kV, 6.6kV, and 11kV).
Installation cost is 10-15% lower than electronic soft starters.
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 20 MW
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 Compensator, 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 present; 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 inferior flexibility
when it comes to starting current selection of the motor. This results in high bypass current.
Case Studies:-
1. 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
2. Iron and Steel Company:
Transformer MVA : 11 MVA, 11 KV
Internal Impedance : 8%
Motor Details : 3.2 MW, 11 KV
Base Load : 225 KW (Aux LT loads)
Sl. 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)
% Overloading of 11 MVA Transformer
1
DOL Starting
6.5
225
19.43
24821
226%
Achieved parameters after commissioning
2
Starting with SS and support of PF correction of 2000 KVar
2.75
3450 (1 motor running with other base load 225 KW)
7.2
10437
No Overloading
3. Oil Exploration Site Captive Power Plant
Generator: 10 MVA, 0.8 PF (two generators 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, 6600 V, 138.1
A full load current; DOL current: 650%
Site Results of Starting
Sl. 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
<2.5 Ifl
<2%
8 sec
2X5MW GTG
4. Irrigation Pump :
Transformer: 31.5 MVA, 220KV/11KV, 10.5%
Motor: 10.5 MW, 11KV, 562A, Synchronous
Gen KVAR: 10 * 0.6 * 1.4 = 8.4 MVAR, considering an overload of 40% in
reactive power
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
Parameter
Commitment
At Site
Ist
3.5 x IFL (889 A)
3 x IFL (762 A)
Tst
45 sec
34 sec
V drop
Less than 1100 Volts (10%)
Actual 750 Volts (6.38%)
6. Steel plant
Soft Starter : Based on Series reactor principle as per IS5553
Part-3/IEC60289 (old standard), IEC60076-6
Motor : 4200 KW, 11 KV, 50 Hz, 1500 rpm, Full Load Current: 254 Amps
Application : Waste Gas Fan
Grid Capacity :
Starting Current: Committed – 3.5 x I-FL (889 A), Actual – 3 x
I-FL (762 A)
Voltage Drop : Committed – less than 1100 Volts (10%), Actual –
750 Volts (6.38%)
Starting Time : Committed – 45 sec, Actual – 34 sec
