all over the world, causing problems in several ways:
•
Electrical problems due to voltage and current transients
arising from Direct-On-Line or Star-Delta starts. The
transients may overload the local supply network and
cause unacceptable voltage variations that interfere with
other electrical equipment connected to the network.
•
Mechanical problems that address the entire drive chain,
from motor to driven equipment, causing a big need for
service and repair work.
•
Operational problems, such as damage to products on
conveyor belts.
•
Water hammering and pressure surges in pipe systems
when starting and stopping pumps.
The financial consequences of the problems above are
considerable. Every technical problem and every breakdown
costs money in repairs and lost production.
By choosing ABB’s softstarter, all of these problems could
be avoided. Whether the choice is the PSR, PSS, PSE or the
PST(B), ABB’s softstarters all allow smooth start and stops
while keeping mechanical and electrical stresses to a minimum.
ABB offers four different ranges of softstarters to cover
every customer need for solutions with motor sizes up to
1800 A. This page describes the main characteristics of the
different softstarter ranges.
PSR — The compact range
The PSR softstarter is the most compact of all the softstarter
ranges. A compact softstarter also allows for the design of
compact starting equipment. A PSR together with a MMS
(manual motor starter) makes up a far more compact starting
solution than a Star-Delta starter, for instance.
By including a built-in by-pass the energy losses inside the
softstarter are reduced. And with only three potentiometers,
the setup of the PSR could not be easier. Still, the optimized
ramping characteristics will ensure a very smooth start and
stop for all applications.
PSS — The flexible range
The PSS is the most flexible of the four softstarter ranges from
ABB. It allows both in-line and inside delta connections. As
with the PSR, few settings are needed to get it up and running.
Connecting an external current transformer makes it possible
to activate the current limit function which will allow you to
keep the current at a pre-set level also when starting heavy-
duty applications. The PSS softstarter is the ideal solution
when looking for a robust solid state starting solution where
handling many starts per hour is required.
PSE — The efficient range
The PSE softstarter is the world’s first compact softstarter
with both built-in electronic overload for motor protection
and torque control for excellent control of pumps. A compact
design, packed with functionality, makes the PSE a very
efficient starting solution.
An illuminated, language neutral display and a four button
keypad makes it easy to take advantage of all the advanced
features of the PSE softstarter. The display provides all the
necessary information both during ramping and continuous
operation.
PSR18 - 600 - 70
Control supply voltage: 70 = 100-250 V AC
11 = 24 V AC/DC
Operational voltage: 600 V
Current rating: 18 A
Softstarter range
PST(B) — The advanced range
The PST(B) softstarter is the most advanced softstarter in
the range with almost all imaginable functionality included.
Advanced protection of the motor, softstarter and load ensures
a trouble-free operation. Problems are detected before the
motor needs to be stopped thanks to a pre-warning system
that minimizes downtime.
The torque control of the PST(B) was developed in cooperation
with well-known pump manufacturers to ensure the best
possible stop of pumps, without the risk of water hammering
and pressure surges.
With the full-text LCD display in your own language, pre-
programmed application settings and event logging, setup and
operation could not be easier.
By using the ABB‘s FieldBusPlug, you can decide at any time
which bus protocol to use. The fieldbus system will allow you
to setup, control and monitor the softstarter.
From the moment the first electric motor was developed,
engineers have tried to come up with ways of avoiding
the electrical and mechanical problems that usually occur
when starting a motor. High inrush currents, current spikes
and excessive mechanical wear are some of the problems
that need to be avoided. One way is to use a Star-Delta
starter. This method is for many applications an insufficient
solution since it handles neither problems with current
spikes or torque peaks nor provides a way to perform a
soft stop. A softstarter on the other hand, will provide far
better performance during the start and allows for soft
stops of the motor.
ABB has been producing softstarters since the beginning of
the 1980’s. Over 30 years’ experience has been incorporated
into the design of today’s product ranges. Modern power
electronics matched with smart circuitry and software gives
users of ABB‘s softstarters, with several state-of-the-art design
features, superior control of current and voltage levels during
motor start and stop.
The solution to both mechanical and electrical problems
AC motors, “the workhorses of the industry”, are used to
drive fans, crushers, agitators, pumps, conveyors and more.
Depending on the motor installation, torque and current peaks
occur. These peaks are everyday reality for production plants
PSR
•
–
–
–
–
–
–
–
–
–
–
–
–
–
–
O
–
–
PSS
–
•
–
–
–
O
–
–
–
–
–
•
–
–
–
–
–
–
PSE
•
–
•
•
•
•
•
–
–
–
•
•
•
–
•
O
O
O
PST(B)
• 1)
•
O
•
•
•
•
•
•
•
•
•
•
•
•
•
•
O
• Standard O Optional – Not available
Built-in by-pass
1) on PSTB
Inside delta connection
Coated PCBs
Display and keypad
Torque control
Settable current limit function
Electronic motor overload protection
PTC input for motor protection
Phase imbalance protection
Phase reversal protection
Locked rotor protection
Thyristor overtemperature protection
Underload protection
Programmable warning functions
Analog output
FieldBus communication
Event log
External keypad
Motor voltage
V
I
Motor current
Softstart
T
Torque
Star/Delta
DOL
100 %
DOL
Star/Delta
DOL
Star/Delta
70 %
58 %
Adjustable
ramp slope
30 %
Softstart
Softstart
Time
Motor speed
Motor speed
Graphs showing the basic differences between Direct-On-Line starting (DOL), Star-Delta starting and soft starting in terms of the motor voltage (V), motor current (I) and motor torque (T).
4 Softstarters | 1SFC132005C0201, rev. M
1SFC132005C0201, rev. M | Softstarters 5
Applications
Applications
Water is the most important resource in the world and water facilities can be found everywhere. Examples of water
applications are freshwater and wastewater systems, circulating water for heating, cooling and irrigation.
Pumps
Fans
Common questions:
– How to avoid extended voltage drops due to long
starting time?
– Use ABB’s softstarter equipped with current limit to
keep control of the starting current.
– How to extend the life of the driving belts?
– Our softstarters will reduce the mechanical stress during
start, thus avoiding slipping belts.
Wastewater transportation
• Influent and effluent pumps
• Treatment pumps and fans
Industrial use
• Process feed-water pumps
• District heating pumps
• Cooling water pumps
Drinking water distribution
• Slurry pumps
• Distribution pumps
• Booster pumps
Irrigation
• Intake pumps
• Distribution pumps
Water transmission
• Transfer pumps
• Distribution pumps
• Booster pumps
Desalination
• Intake pumps
• Brine pumps
• Booster pumps
• High pressure pumps
• Drinking water pumps
– How to ensure the operation of the fan?
– A softstarter with underload protection will detect broken
belts, making the operator immediately aware of the
problem.
Compressors
Water treatment
• Treatment pumps
Common questions:
–
How to ensure a long life of the compressor?
– Using a softstarter for starting will reduce the accelerating
torque, thereby minimizing the mechanical stress.
– How to build a compact compressor unit?
– Using a compact softstarter like PSR or PSE will allow a
much more compact starting equipment than for instance
a Star-Delta starter.
Effluent water
• Effluent pumps
Raw water intake
• Raw water intake pumps
Waste incineration
• Effluent pumps
• Fans
• Conveyors
Effluent water
• Effluent pumps
Raw water supply
• Feed-water pumps
Conveyor belts
Common questions:
– How to avoid voltage drops when starting?
– ABB’s softstarter will reduce the starting current
and thereby avoid the voltage drops.
– How to avoid water hammering when stopping?
– Use our softstarters equipped with an optimized
stop ramp. Or even better, with torque control.
– How to ensure high reliability in harsh environments?
– Use our softstarters equipped with coated circuit
boards to better withstand those environments.
– How to protect my pumping equipment in the best
possible way?
– Use ABB’s softstarters equipped with our special
designed protections such as overload, underload,
and locked rotor protection.
Common questions:
– How to reduce the need for service and repair of the
conveyor belt?
– A softstarter from ABB will ensure starts with minimal
mechanical stress on the conveyor belt.
– How to avoid that the conveyor belt is running in the
wrong direction?
– Use a softstarter with phase reversal protection.
– How to improve the efficiency of the conveyor belt?
– Using softstarters with high and low current warnings
allow you to load on and off the conveyor belt.
– How to ensure a successful start even after longer times
without operation?
– A softstarter with kick start function will provide sufficient
torque to be able to overcome the initial high friction from
a temporary jammed belt.
6 Softstarters | 1SFC132005C0201, rev. M
1SFC132005C0201, rev. M | Softstarters 7
PSR – The compact range
Description
The PSR range is the most compact of all ABB’s softstarter
ranges. The compact PSR range makes it possible to fit many
devices into the same enclosure. A PSR together with a MMS
(manual motor starter) makes up a far more compact starting
solution than a Star-Delta starter, for instance.
Flexible mounting
PSR softstarters from 3 to 45 A are possible to mount on a
DIN-rail, ensuring quick and easy mounting. Naturally, all sizes
can be screw mounted.
Few settings
The setup of the PSR is easily done and confirmed using the
three clearly marked potentiometers on the front.
Built-in by-pass for energy saving
The built-in by-pass on all sizes does not only save energy;
it will also ensure the most compact ABB’s softstarter design
and reduce the installation time. Thanks to the reduced heat
generation, the softstarter can be mounted inside high IP class
enclosures.
Suitable for stopping pumps
Even without using torque control, the PSR range is designed
to reduce water hammering. Compared to the direct stops of a
Star-Delta starter or a DOL starter the PSR is superior. See the
stop ramp with step-down voltage below.
System concept with manual motor starters
All PSR softstarter sizes can easily be connected to the
corresponding manual motor starters from ABB by using
the special designed connection kits. This makes both the
mounting and the connection easier and will provide a very
compact starting solution containing short circuit and thermal
protection, isolation function and soft starter - everything that
you need.
PSR – The compact range
Overview
PSR3 ... PSR16
Softstarter, type
Normal start
In-line connected
PSR3
PSR6
3
6.8
3
6.1
PSR9
4
9
5
9
PSR12
5.5
12
7.5
11
PSR16
7.5
16
10
15.2
PSR25 ... PSR30 PSR37... PSR45
PSR25
11
25
15
24.2
PSR30
15
30
20
28
PSR37
18.5
37
25
34
PSR45
22
45
30
46.2
PSR60 ... PSR105
PSR60 PSR72 PSR85 PSR105
30
60
40
59.4
37
72
50
68
45
85
60
80
55
105
75
104
(400 V) kW
1.5
IEC, max. A
3.9
(440-480 V) hp
2
UL, max FLA
3.4
Product description
•
Wide rated operational voltage 208–600 V
•
Rated control supply voltage 24 V AC/DC or 100–240 V AC
•
Rated operational current 3–105 A
•
Wide ambient temperature range, -25 to +60 ºC
•
Built-in by-pass on all sizes, saving energy and reducing
installation time
•
Potentiometer settings
•
Run signal relay on all devices
•
TOR signal relay on PSR25 … PSR105
•
Optional fieldbus communication using Profibus, Modbus,
Devicenet or CANopen
•
DIN rail mounting on PSR3 … PSR45
•
Screw mounting on all sizes
•
Connection kits for easy connection with ABB’s manual
motor starters
•
Sophisticated algorithm eliminating the DC-component and
thereby providing excellent starting performance
400 V, 40 ºC
Manual motor starter (50 kA) type
Using manual motor
starters type 1 coordination
MS116
will be achieved
Using gG fuses type
1 coordination will be
achieved
Suitable switch fuse for the
above gG fuses
Fuse protection (50 kA) gG Fuse
10 A
16 A
25 A
32 A
50 A
63 A
100 A
125 A
200 A
250 A
MS132
MS450
MS495
—
Switch fuse, type
OS32GD
OS125GD
OS250D
Overload protection is used
Thermal overload relay
to protect the motor from
over heating
Line contactor, type
The line contactor is not
required for the softstarter
itself but often used to open
AF9
if OL trips
By-pass contacts
TF42
TF65
TF96
TF140DU
AF12
AF16
AF26
AF30
AF38
AF52
AF65
AF80
AF96
AF116
Using by-pass will reduce
the power loss and allow
more starts per hour
Built-in
Settings
2 Step down
1
2
3
Start = 1 ... 20 sec
Stop = 0 ... 20 sec - including the step down voltage.
Step down = 2% reduction for each second increased stop ramp
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Microcontroller MCU
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