ABB HF Series User manual

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MANUAL

Electronic compact starter

HF range

2ELECTRONIC COMPACT STARTER | MANUAL

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Electronic compact starters are

becoming more and more popular

due to their compactness and

flexibility.

Based on hybrid technology,

ABB’s 22.5 mm-wide HF-Series

provides direct on-line and

reversing motor starter protects

against overload, phase failures

and phase asymmetry. A safety

range supports the devices use in

safety applications.

This manual provides an overview

of the product and its

applications to assist in the

implementation and use of the

electronic compact starter.

3ELECTRONIC COMPACT STARTER | MANUAL

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Table of contents

1 Product overview 5

Benefits 8

Product combinations 9

Explanation of terminals 9

2 Safety and conformity 14

General safety arrangements 14

Safety arrangements in explosive areas 15

Conformity 15

3 Functions 16

Direct on-line starters 17

Reversing starters 20

Setting the nominal current 24

4 Motor protection 26

Thermal overload protection 27

Phase asymmetry 28

Phase failure 28

Signaling 29

Function Test 32

5 Installation and de-installation 33

Installation 33

Derating 34

De-installation 34

6 Commissioning 35

Commissioning the terminals 35

Main and load terminal connection 35

Control terminals 36

4ELECTRONIC COMPACT STARTER | MANUAL

Reset terminals 38

Signaling relay terminals 38

Short circuit protection 39

7 Circuits with brakes 43

Motors with a 230 V AC brake 43

Motors with a 400 V AC brake 44

8 Typical circuits for HF range types with

integrated emergency stop 45

Prevention of cross-error circuit 45

Wiring standard variants 46

Wiring safety variants - DOLE 47

Wiring safety variants - ROLE 53

9 Technical data 59

10 Dimensional drawings 60

11 Annex 62

The electronic compact starter HF-range is used for switching functions of three-phase induction motors (AC-53a)- as well

as direct on-line and resistive loads (AC-51).

The range is available as direct on-line starters (HFxx-DOL) with overload protection as a standard feature and with a safety

design for emergency applications (HFxx-DOLE) with a safety-related shutdown.

Reversing starters (HFxx-ROL) with overload protection and with emergency switch-off function (HFxx-ROLE) are also

available. The standard- DOL/ROL series and the DOLE/ROLE safety series come with electronic overload protection already

integrated. For applications where only a reversing starter is needed, the HFx-R is available – this starter does not have an

integrated electronic overload protection but is the only starter able to control single-phase motors.

For safety applications, a safety relay (e.g. SSR10 or USR10), signal devices and additional devices are required. The manufac-

turer of a plant or a machine is responsible for ensuring its safe functioning with safety-related components.

Definition

In this manual, 'HF range' and 'Electronic Compact Starter – ECS' refer to all variants of ABB’s electronic compact starters.

They complement ABB’s motor starting solution offer, providing the right product for various applications up to

3 kW/400 V AC.

Conformity

The HF-range complies with the following standards:

• IEC 60947-1

• IEC 60947-4-2

The safety related variants comply with the following standards:

• EN 62061:2005

• EN ISO 13489-1:2010

• IEC 61508-1:2010

• IEC 61508-2:2010

• IEC 61508-3:2010

Approvals

For confirmation of approvals please visit:

https://new.abb.com/low-voltage/products/motor-controllers/electronic-compact-starters

Basic function

In general, the easiest way to start a motor is with a contactor. Combining it with a protective device against short circuit,

overload protection and in many cases also an isolation device, this combination is then called a motor starter. For reversing

applications where the motor operates in both directions, an additional contactor is needed. This conventional solution –

contactors in combination with overload relays - can be replaced by the electronic compact starter.

5ELECTRONIC COMPACT STARTER | MANUAL

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1 Product overview

Applications

The electronic compact starter is used mainly in the OEM-segment, whereever space is limited, long lifetime is necessary and

frequent switching is need. Applications include:

• Conveyor technology

• Logistics

• Production machines

• Machine tools

• Small elevators

• Pumps and compressors

• Solar tracker

• Snow guns

Hybrid technology

In order to achieve the greatest possible advantage, hybrid technology combines two technologies. Semiconductors switch

the motor on and off with bypass relays used while the motor is running. A microcontroller ensures the right interaction

between the components, shown in figure 1 below. Before starting the motor, all relays are opened as can be seen in figure 1.

When the relays K1 and K2 are energized, the currents I1, I2, I3 are still approx. zero, see figure 2.

——

01 Semiconductors with relay bypass 02 Equivalent circuit diagram 2

∆∇

▶

↑Contact energized

3 ~

L1 L2 L3

V1 V2

K3 K3 K2

K1 K1 K2

▶

↑ ↑

↑

∆∇

3 ~

L1 L2 L3

∆∇∆∇

V1 V2

K3 K3 K2

K1 K1 K2

▶

6ELECTRONIC COMPACT STARTER | MANUAL

The microcontroller powers the V1 and V2 semiconductors. Currents I1, I2 and I3 flow so that the motor runs, as highlighted

in red in figure 3.

Semiconductors generate significant losses in the form of heat dissipation. In order to reduce this loss of power, V1 and V2

are now bypassed by the K3 relays and hence turned off. The bypass relays now carry the current while the motor is running,

reducing power losses.

The same method is used for switching off the motor: the semiconductors are activated by the microcontroller and take over

the current from the bypass relays that then open. After that, the motor is switched off by de-energizing V1 and V2 so that

the current equals zero. At the end, the K1 and K2 relays are opened.

——

03 Equivalent circuit diagram 3 04 Equivalent circuit diagram 4

Hybrid technology enables arc-free switching and helps extend the lifespan because the relay switching that would usually

cause arcs is prevented.

The typical wearing away of contact material seen in standard electromechanical devices is eliminated thanks to the smart

use of the semiconductors. Up to 30 million electrical switching lifecycles, 7200 switching cycles per hour and multifunction-

ality is provided in only 22.5 mm width.

3 ~

L1 L2 L3

∆∇∆∇

V1 V2

K3 K3 K2

K1 K1 K2

↑Contact energized

↑ ↑ ↑

↑

3 ~

L1 L2 L3

∆∇∆∇

V1 V2

K3 K2

K1 K1 K2

↑Contact energized

↑ ↑ ↑

↑

▶

7ELECTRONIC COMPACT STARTER | MANUAL

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1.1 Benefits

Up to 90% less space required

ABB's electronic compact starter saves cabinet space, and is especially effective for group mounting.

The starter is just 22.5 mm wide and yet still provides motor starting functionalities with motor

protection and safety embedded.

Integrated safety function

Protect your people with an emergency stop version that complies with SIL 3, PL e safety standards.

Extend the life of your equipment and reduce maintenance costs with service lives that are ten times

higher than electromechanical solutions.

Up to 75% reduced time in wiring

Wiring time during installation is cut to a minimum with motor protection, reversing function and

emergency stop already integrated in the product. With just one component to install, the risk of

wiring errors is lower. Separate overload protection is no longer needed.

Space saving

Safety and

protection

Easy to install

8ELECTRONIC COMPACT STARTER | MANUAL

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1.2 Product combinations

In combination with the HF-range, ABB recommends using power supply CP-E 27/0.75 (1SVR427030R0000). With an output

current of 0.75 A, it is possible to connect up to 18 electronic compact starters.

Function Product Description Product name Order code

Power supply Power supply for compact

starters

24 V DC rated output voltage CP-E 24/0.75 1SVR427030R0000

Control input Pilot devices NO modular contact block MCB-10 1SFA611610R1001

Push button MP2-10x 1SFA611101R100X

Modular holder MCBH-00 1SFA611605R1100

DIN-rail adaptor MA1-8131 1SFA611920R8131

Remote reset Reset button 1 NO

Contact block for rear

mounting

MCB-10B 1SFA611610R2001

Push button MP1-10x 1SFA611100R100X

Modular holder MCBH-00 1SFA611605R1100

Emergency switching off Emergency switch Switch CE4P-10R-02 1SFA619551R1051

Interlocking - switch Switch Two-position selector switch M2SS5-10B 1SFA611204R100X

Modular holder MCBH-00 1SFA611605R1100

NO modular contact block

(2 pc.)

MCB-10 1SFA611610R1001

NC modular contact block

(2 pc.)

MCB-01 1SFA611610R1010

Safety related applications Safety relay Sentry SSR10 2TLA010050R0000

Sentry USR 10 2TLA010070R0000

Table 1 Product combinations

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1.3 Explanation of terminals

Divergent details are shown for each type in the following chapters, in which the various functions of the terminals are also

explained.

All settings and adjustments are made directly at the electronic compact starter. The exception is HF9-R-24VDC where no

adjustments are possible and no protection function is integrated.

The LEDs have multiple functions, such as indicating the exact parametrized nominal current (see chapter 3.3), displaying the

status for diagnostics (see chapter 4.4) and showing the operation status.

9ELECTRONIC COMPACT STARTER | MANUAL

Terminal indications of DOL- and ROL- types

No. Indication HFxx-DOL-24 V DC HFxx-ROL-24 V DC

1UsInput control supply voltage Input control supply voltage

2HFxx-DOL: ON

HFxx-ROL: R, L

Connection point for ECD - external control

device for starting the motor

Connection point for ECD - external control

device Right /Left rotation

3MAN, RES, AUT Acknowledgement inputs Acknowledgement inputs

495,96,97 Switch over contact - fault signaling output Switch over contact - fault signaling output

5Potentiometer Potentiometer for the rated operational

current "Ie" of the motor

Potentiometer for the rated operational

current "Ie" of the motor

6PWR LED PWR LED (green) PWR LED (green)

7ERR LED ERR LED (red) ERR LED (red)

8Iadj LED Iadj LED (yellow) Iadj LED (yellow)

9DOL: ON LED

ROL: R-, L-LED

ON LED (Rotation) R-LED (Right rotation)

L-LED (Left rotation)

10 Reset button Reset after trip Reset after trip

11 2/T1, 4/T2, 6/T3 Main circuit output Main circuit output

12 1/L1, 3/L2, 5/L3 Main circuit input Main circuit input

13 Metal latch Metal latch for fixation to the

DIN rail

Metal latch for fixation to the

DIN rail

Table 2 Explanation of terminals and LED status indicator of DOL, ROL types

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05 Explanation of terminals and LED

status indicator of DOL-ROL- types

10 ELECTRONIC COMPACT STARTER | MANUAL

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