TECHNICAL SPECIFICATIONS FOR HARMONICS FREE SERIES REACTOR

TECHNOLOGY BASED SOFT STARTER

The motor soft starter design as per the IS 5553 [part 3] / IEC 60289/076 working on the principle series
Reactor for currant limiting of 3 Phase motor
This specification covers the requirement for LT/HT HARMONICS FREE SERIES REACOTR [HFSR] soft starters from
415 V TO 11 KV. The product shall comply with the requirements of IS 13947 Part-4 for Low voltage switchgear
and control gear as well as all guidelines of IS 12661[part 1]. Any material and component not specifically stated
in this specification but necessary for trouble free smooth operation of the equipment and the accessories must
be as per the list of standards in table 2.0 listed on page no. 05.

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1. The HFSR Soft Starter shall work on the principles of Harmonics free Series Reactor [HFSR]
Technology. It should follow the [IS standard 5553[part 3] year 1990 / IEC 60289/076 year
1988] for the design of the current limiting reactors which is the prime and key component of
the soft starter.
2. The Soft starter shall be designed for Supply Voltage Variation of 10% & Frequency variation
5 %.
3. The HT Soft Starter shall be rated corresponding to the Motor Power & shall be capable of
Operating satisfactorily with the Motor under the various loading & starting condition of the
Motor over the entire Operating Range. The Soft Starter rating offered shall not be less than
the rated KW of the Motor.
4. The HFSR Soft Starter shall reduce the starting current of the Motor at least to 60% of the direct
online (DOL) starting current of the Motor & should have a provision to further reduction of
starting current up to 50 % if motor / load torque permits so. The Soft starter shall control the
starting torque in such a manner so as to effect smooth starting of the Motor Drive is achieved.
Further line current reduction should be [if required] achieved by the use of dynamic
compensator. For further system current reduction a standalone dynamic compensator can be
used to reduce the current up to 1.5 X FLC.
5. The HFSR Soft starter shall be provided with suitably rated digital ammeter to indicate the
Motor current during starting.
6. The Soft Starter shall be so rated as to allow at least three starts equally spaced per hour or one
hot start.
7. The Reactor Windings of HFSR Soft Starters shall be with insulation Class H; maximum
temperature of winding shall be limited to that of Class B. The HFSR reactor modules must be
all weather and vermin proof epoxy casted. Three reactors for three phases must be
independent in construction for easy maintenance and cooling, any reactor should be easily
removable from the panel without disturbing the remaining two. The reactors should be clearly
visible for inspection as well as ventilation and should not be encapsulated or enclosed in any
structure. Suitable TAPs should be provided for onsite current adjustment.
8. The Reactors of HFSR Soft Starter shall be of air core design for smooth linear acceleration and
high efficiency, Natural Air Cooled [meeting all the specification of standard IS 5553[part3] IEC
60289/076] & shall not lead to generation of Harmonics and humming noise during starting
process. No iron or magnetic core should be used for the series reactor as to avoid the eddy
currents, noise/vibrations and heat generation as well as to avoid core saturation and power
losses.
9. The HFSR Soft starters shall have the built in facility to bypass the Reactor near to Full Speed of
the Motor by suitable vacuum device/power device so that the voltage to the Motor is equal to

A. Technical description of the methodology and specification of soft starter.

the supply voltage. The bypass event must be a close loop operation controlled by current and
Temperature monitoring Relay [CTMR].
10. Current and Temperature Monitoring Relay [CTMR]: should be a microcontroller based
intelligent device to control the bypass event for HFSR soft starter. The CTMR must be in-house
tested for EMI/EMC interference. The CTMR must protect the HFSR soft starter from:
Interlock failure
Over current protection
Bypass device failure
Control voltage failure
Total number of starts
Over temperature fault
CTMR must have a proper visual annunciation for the faults.
11. The HT Soft Starter shall have suitable hour meter and operation counter for counting
motor running hours & counting no. of startstop operations of the motor.
12. The HT Soft Starter shall have Anti Condensation Heater with switch & Thermostat. The Heater
shall have interlocking in such a way that it is switched OFF when Motor is in run mode.
13. The HT Soft Starter shall have suitable rated control switchgear like Contactors, Timers, Push
Buttons & Indication Lamps.[ all components should follow the IS standard as per the table 2]
14. The HT Soft Starter shall be indoor, metal clad with separate metal enclosed compartments
for
I. Control, Metering & Push Buttons with indicating Lamps
II. Power Switchgear
III. HFSR Compartment
IV.Power Cable Terminations.
15.
Each cubicle of HT Soft Starter shall be fitted with a label in the front & rear of the
cubicle, indicating the panel designation, rating & duty. Each relay, instrument, switch, fuse &
other devices should be provided with separate labels.
16. The Soft Starter shall be housed in a sheet steel enclosure of thickness not less than 2 mm &
internal frame 3 mm. The enclosure shall be painted with powder coating corrosion resistive
paint as per IS-5 such as Epoxy or Polyurethane. The degree of Protection shall be IP 51. The
enclosure should be only CNC fabricated.
17. The HT Soft Starter should be suitable for up to 50 degree Ambient Temperature and Altitude
up to 1000 m.
18. All the equipments used in the soft starter panel must meet appropriate IS/IEC standards and it
should follow the standard practices and specifications [ refer table 2.0 ]

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The manufacturer should be designing and manufacturing the air core based HFSR type [IS 5553/IEC
60289] soft starters for at least 3 years. The manufacturer should have at least five performance
certificates for air core based soft starters for at least 500 kW and above rated motors with minimum
25 units supplied over 3 years of span.

Table 1.0: Technical Particulars:

Sr. No.
1

Description
Type of Soft starter

Unit
HFSR

Particular
Air core based Series Reactor as Per IS 5553 Part 3
IEC 60269/076

KV
%

3-3.3
+/- 10

6-6.6
+/-10

10-12
+/- 10

0.380-0.690
+/-10

Hz
%

50/60
+/- 5

50/60
+/- 5

50/60
+/- 5

50/60
+/- 5

Basic Technical Parameters

2
2a
3
3a
4
5

Supply Voltage
Allowable Voltage
Variation
Supply frequency
Supply Frequency
Variation
Motor Ratting
Application

HP/KW

Maximum System
Voltage

KV

3.6

7.2

12

1.1

KV
RMS

7.6

14.2

28

2.5

KV
Peak

37

60

75

9a

Short Duration power

frequency withstand
voltage
1.2/50 micro sec.
impulse
withstand voltage
Short Circuit
Withstand
Short time

9b

Dynamic

10

Reference Ambient
Temperature
Altitude Above MSL
Method of connection

50

50

50

50

10a
11
Built and panel particulars

KA
KA
RMS
KA
Peak
C

Meters 1000
1000
Line/neutral Line/neutral

12

Housing

13

Paint

IS

14
15
16

Degree of protection
Colour finish shade
Bus bar ratting and size

IP

17

Bus Bar insulation

18

Cable entry

1000
1000
Line/neutral Line

sheet steel enclosure of thickness not less than 2 mm &

internal frame 3 mm. CNC FABRICATED
powder coating corrosion resistive paint as per IS-5 such as
Epoxy or Polyurethane
Standard: 51. On request 54
Interior : Glossy white Exterior : RAL 7032
Suitable as per application.
Bus bars should be rated 3 times the motor rated current.
Non conductive temperature resistant heat shrink sleeve.
High voltage sleeve.
Top/bottom: separate cable entry for power and control
cables. Covered by non magnetic plate.

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Comments :

Operational Specifications : site and motor specific

19

Bypass Device

20

Control Voltage

21

Space heater and

lighting
Current transformer
Type
Class

22
22a
22b

Vacuum
device
110/220 V
AC/DC
240 VAC

Vacuum
device
110/220 V
AC/DC
240 VAC

Vacuum
device
110/220 V
AC/DC
240 VAC

Cast resin bar Cast resin bar Cast resin bar

Class E or
Class E or
Class E or
better
better
better
15 VA
15 VA
15 VA
Notes: Customer scope of supply for standard models
Starting interlock with incomer 3.3 kV / 6.6 kV / 11 kV vacuum Circuit Breaker / VC Panel
Trip circuit interlock
Start mode signal interlock
Emergency stop button interlock

Power
contactor
Internally
generated
240 VAC

Cast resin bar

Class E or
better
15 VA

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B. Basic Guide lines for In factory testing as per IS 5553 :

The following Tests shall be carried on the soft starters during inspection at the Manufacturers Works:(i) Visual Check:
(a) Bus sizes as per wiring diagram.
(b) Component check as per bill of material.
(c) Name Plate as per Format.
(ii) Dimensional Check:
(a) Overall dimensions as per GA Drawing
(b) Minimum line to line and line to earth clearance.
(iii) Insulation Testing: Megger test with 2500 V Megger before HV Test: The required value between any
two phases (6 readings) shall not be more than 50 mega ohms.
Megger test as above after HV Test.
(iv) Control Testing: Control Logic check as per wiring diagram.
(v) Routine Tests:
(a) HV Test @ 1.1 KV for 415V, @ 7.2 for 3.3 KV , 14.2 KV for 6.6 KV & 28 kV for 11 KV system @ 50 cycles
for 1 minute
(vii) Bus bar Tests:
(a) The bus bar shall be tested 800 A.
(b) Temperature rise test for Bus bar and Vacuum Contactor shall be carried out for one panel.
Temperature rise shall be within 10 degrees.
(ix) Performance Tests & Internal Test Reports [ITR] should be submitted
(x) CTMR fault condition test: virtual fault situation should be created for:
Interlock failure
Over current protection
Bypass device failure
Control voltage failure
Total number of starts
Over temperature fault
CTMR must have a proper visual annunciation for the faults.
A complete Internal Test Report [ITR] for HV/mechanical/EMI-EMC test report should be witnessed

Manufacturer Scope of supply :

Adjustable taps on HFSR MODULE for starting current selection at site during commissioning
Individual lock and key for every enclosure
The soft starter should have CTMR protection relay pre-installed for safety and protection of the soft starter.

Table 2.0: Relevant IS / IEC standards for all major and minor components used during design and
manufacturing of the HFSR soft starter:
Sl
No.

Specifications

IS No.

a) Series Reactor

5553 (Part 3)

b)Specifications For High Voltage Motor starters

12661 (Part-1)

IEC No

13947-2

60947-2

3 High Voltage Circuit Breakers

13118

62271-100

4 Low Voltage Fuses

13703

60269

13947-4-1/2

60947-4-1/2

6 Temperature Rise In Reactors

2026

60726

7 Power Connectors Cable Termination

5561

----

8 Current Transformers

2705

60044

9 Voltage Transformers

3156

60186

10 HT Contactor

9046

60470

11 Indicator Lamps

1901

----

12 Time Switch

1766

5 Low Voltage Contractors & Motor Starters

13947-1

60947-1

14 Code of practice for earthling

3043

----

15 HT Contactor

9046

60470

16 Marking & Identification of Conductors and Terminals

11353

----

17 3 Phase Inductor Motor

325

----

18 Marking of Insulated Conductors

5578

----

19 Porcelain Post Insulators With Voltages > 1000 V

2544

----

20 Capacitors used for dynamic compensator

13925

871

13 Degree of protection

Note:
All the components specified other than the list as table 2.0 must bear an appropriate standard.
The columns in grey in table 1 indicate the value must be decided by the end user as per the
site/application/system requirement.
Magnetic core based solution must not be used to ensure safety of the system as a whole.

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2 Low Voltage Circuit Breakers

60289/60076