Softstarter EURA® HFR-1000

Softstarter EURA® HFR-1000

PREFACE

Thank you for your choice of EURA DRIVES SoftStarter.

As the return of your trust we will provide the perfect quality and wholehearted service to you.

Adopting modern control theory, modularization design, DSP controlled, high quality material and parts/components, together with advanced SMT manufacturing engineering, HFR1000 series softstarter is a high tech product combing digit, computer and modern automatic control theories. It is characteristic of high performance, high quality and skinny volume, and is widely applicable for starting and protection of three-phase motors in various industries.

Notes

This instruction manual provides information with respects to installation, parameter-setting, trouble-diagnosing and proper operation. This manual should therefore be kept properly and a careful reading shall be required before any operation attempt to avoid any accidental casualties or damage(s) to the facilities.

Special Notice:

Installation, operation, maintenance or checking to this product shall be required before reading carefully this instruction manual and ensuring proper use.

Power shall be disconnected before any wiring. Never touch power terminal with hand or conduct object. Never put or drop foreign substance into soft starter.

When using the bypass contactor, please connect the motor according to the recommended diagram in the user‟s manual, that‟s in order to keep the

HFR1000

output exact consistency of softstarter and motor. Otherwise softstarter and motor will be damaged.

Please do not take magneto ohmmeter to measure the insulated resistance between input and output. Otherwise the IGBT and control PCB will be damaged because of high voltage. Please use the magneto ohmmeter to measure the resistance between each phase and between each phase with ground. Also please note that firstly use 3 cables short circuit the each three-phase of input and output separately and take out the entire plugs in control PCB.

Connect input terminals R, S and T to urban power supply of

400V; connect output terminals U, V and W to motor.

Grounding terminal PE shall be properly earth connected

(grounding impedance not exceeding 4Ω).

When terminals R, S and T are connected to power supply of 400V and output terminals U, V and W are not connected to motor, it is normal that the voltage of U, V and W is AC400V. The voltage is got by leakage current of module. After U, V and W are connected to motor, the voltage will clear away.

Capacitance can not be connected to the output of soft starter, but capacitance can be connected to the input of soft starter when it is used for improving power factor.

·2·

CONTENTS

I. Product ………………………………………………………………..

1.1 Nameplate ……………………………………………………

1.2 Model Illustration……………………………………………

1.3 Appearance……………………………………………………

1.4 Technical Specifications ……………………………………

1.5 Designed Standards for Implementation……………………

1.6 Safe Instructions………………………………………………

1.7 Precautions……………………………………………………

1.8 Maintenance…………………………..……………………

II. Keypad panel…………………………………………………………

2.1 Panel Illustrations……………………………………………

2.2 Panel Operating ……………………………………………

1

1

1

1

2

2

3

3

4

5

5

6

2.3 Parameters Setting …………………………………………

III. Functional Block Diagram…………………………………………

3.1 Functional Block Diagram………………………………

IV. Installation & Connection …………………………………………

4.1 Power Loop Wiring…… ……………………………………

6

7

7

8

4.2 Wiring Recommended………………………………………….

4.3 Terminal Function……………………………………………

9

10

V. Function Parameters …………………………………………………

11

5.1 Parameters List………………………………………………

5.2 Parameters Instruction………………………………………..

8

11

12

VI. External Dimension and Mounting Size……………………………

VII. Appendix……………………………………………………………

Appendix 1 Trouble Shooting of Keypad Panel Display ……………

Appendix 2 Fault Diagnosis………………………..….. ……………

Appendix 3 Applications ……………….…. …………………………

18

20

20

21

23

Appendix 4 Communication Manual………………………. ………

24

HFR1000

I. Product

This manual offers a brief introduction of the installation connection for

HFR1000 series softstarters, parameters setting and operations, and should therefore be properly kept. Please contact manufacturer or dealer in case of any malfunction during application.

1.1 Nameplate

Taking for instance the

HFR1000 series 15KW softstarter with 3-phase input, its nameplate is illustrated as Fig 1-1.

3Ph: Three-phase input;

400V 50/60Hz: input voltage range and rated frequency.

EURA DRIVES ELECTRIC CO., LTD

SOFTSTARTER IP20

MODEL

INPUT

HFR1015 SCOPE

3PH AC 400V 50/60Hz

RATED

CURRENT 30A

MATCHED

MOTOR

15KW

AC-53b

CODE BAR

TRIP

CLASS

Fig 1-1 Nameplate Illustration

10

1.2 Model Illustration

Taking for instance as the HFR1000 series with 3-phase input

H F R 1 □□□

Adaptive motor power(KW)

1000 Series Bypass Model

EURA Softstarter

1.3 Appearance

The external structure of HFR1000 series softstarter is classified into plastic and metal housings and all the installation is wall hanging type. Good poly-carbon materials are adopted through die-stamping for plastic housing with nice form, good strength and toughness. Metal housing uses advanced exterior plastic- spraying and powder-spraying process on the surface with elegant color.

·1·

HFR1000

1.4 Technical Specifications

Power supply

AC 400V±15%, 50/60Hz (It is supplied by interior, users need not supply power.)

Input power supply AC 400V±15%, 50/60Hz

Applicable motor Common asynchronism motor

Startup mode

Stop mode

Voltage ramp startup (1~120 seconds); current limiting startup

(150~400% Ie); voltage kick startup

Free stop; soft stop (1~60 seconds)

Relay output

Startup frequency

Delay running output; fault output; full voltage output (by pass)

[contact dot: 5A, 250VAC] for frequent or infrequent startup;

Advise: not exceeding ten times per hour

Protection function Out phase, over-load, over current over-heating.

Display

Protection level

Cooling mode

LED nixie tube showing present output frequency, types of faults, and parameters for the system and operation; LED indicators showing the current working status of softstarter.

IP20

Cooling naturally

Installation mode Hanging type

Equipment Location

In an indoor location, Prevent exposure from direct sunlight, Free from dust, tangy caustic gases, flammable gases, steam or the salt-contented, etc.

Environment conditions

Environment

Temperature

Environment

Humidity

Vibration Strength

Height above sea level

-10℃~+50℃

Below 90% (no water-bead coagulation)

Below 0.5g (acceleration)

1000m or below

1.5 Designed Standards for Implementation

GB14048.6-2008 Low-voltage switchgear and control-gear contactors and motor-starters Section2: AC semiconductor motor controllers and starters(include softstarter)

GB14048.6-2008/ EN60947-4-2 Low-voltage switchgear and

Control-gear contactors and motor-starters Section2: AC semiconductor

·2·

HFR1000

motor controllers and starters (include softstarter)

1.6 Safe instructions

Please check the model in the nameplate and the rated value of the softstarter. Please do not use the damaged softstarter in transit.

Installation and application environment should be free of rain, drips, steam, dust and oily dirt; without corrosive or flammable gases or liquids, metal particles or metal powder. Environment temperature within the scope of -10℃~+50℃.

Please install softstarter away from combustibles.

Do not drop anything into the softstarter.

The reliability of softstarter relies heavily on the temperature. The around temperature increases by 10℃, softstarter life will be halved.

Because of the wrong installation or fixing, the temperature of softstarter will increase and the softstarter will be damaged.

Softstarter is installed in a control cabinet, and smooth ventilation should be ensured and softstarter should be installed vertically. If there are several softstarters in one cabinet, in order to ensure ventilation, please install softstarters side by side. If it is necessary

1.7 Precautions

1.7.1 Instructions for use

Never touch the internal elements within 15 minutes after power off.

Wait till it is completely discharged.

Input terminals R, S and T are connected to power supply of 400V while output terminals U, V and W are connected to motor.

Proper grounding should be ensured with grounding resistance not exceeding 4Ω; separate grounding is required for motor and softstarter. Grounding with series connection is forbidden.

Load switch is forbidden at output while softstarter is in operation.

AC reactor or/and DC reactor is recommended when your softstarter is above 37KW.

There should be separate wiring between control loop and power loop to avoid any possible interference.

Signal line should not be too long to avoid any increase with common mode interference.

It shall comply with the requirements for surrounding environment

Series Softstarter”.

1.7.2 Special Warning!!

·3·

HFR1000

Never touch high-voltage terminals inside the softstarter to avoid any electric shock.

All safety covers should be well fixed before softstarter is power connected, to avoid any electric shock.

Only professional personnel are allowed for any maintenance, checking or replacement of parts.

1.8 Maintenance

1.8.1 Periodic Checking

Cooling fan and wind channel should be cleaned regularly to check whether it is normal; remove the dust accumulated in the softstarter on a regular basis.

Check softstarter‟s input and output wiring and wiring terminals regularly and check if wirings are ageing.

Check whether screws on each terminals are fastened.

Check whether softstarter is corrosive.

1.8.2 Storage

Please put the softstarter in the packing case of manufacture.

If softstarter is stored for long time, please charge the softstarter within half a year to prevent the electrolytic capacitors damaged.

The charging time should be longer than 5 hours.

1.8.3 Daily Maintenance

Environment temperature, humidity, dust and vibration would decrease the life of softstarter so daily maintenance is necessary for softstarter.

Daily inspecting:

Inspecting for noise of motor when it is working.

Inspecting for abnormal vibration of motor when it is working.

Inspecting for the installing environment of softstarter.

Inspecting for the fan and softstarter temperature.

Daily cleaning:

Keep the softstarter clean. Clean surface dust of softstarter to prevent dust, metal powder, oily dirt and water from dropping into the softstarter. Inspecting for the fan and softstarter temperature.

Daily cleaning:

Keep the softstarter clean. Clean surface dust of softstarter to prevent dust, metal powder, oily dirt and water from dropping into the softstarter.

·4·

HFR1000

II Keypad Panel

2.1 Panel Illustrations

The panel covers three sections: data display section, status indicating section and keypad operating section

LED shows running current, function code, parameter value or fault code.

4 LEDs indicate working status. Details are as following list.

RUN FWD DGT

FRQ

Fun

Press “Fun” for function code, and “set” for original

parameters.andkeys can be used to select function

codes and parameters. Press “set” again to confirm. “Run” and “Stop/Reset” keys control start and stop. Press

“Stop/Reset” key to reset softstarter in fault status.

Set

Run

Keypad

Indicate Light Status of Softstarter Remarks

RUN○

FWD●

DGT●

FRQ●

Running Status

Light “RUN” is on in running state after startup finished and light is off in standby status.

RUN●

FWD○

DGT●

FRQ●

RUN●

FWD●

DGT○

FRQ●

Delay Status

External control

Light “FWD” is on when delay begins, and light is off after delay ended.

Light “DGT” is on when external control works, and light is off in keypad status.

RUN●

FWD●

DGT●

FRQ○

Current Display

Light “FRQ” is on, and current is displayed when pressing FUN key during the startup process; light goes off when pressing it again,

○ indicates the light is on, ● indicates the light is off

and status is displayed.

·5·

HFR1000

2.2 Panel Operating

All keys on the panel are available for user.

Keys

按键

Names

Fun

Remarks

To call function code and switch over display mode.

Set To call and save data.

Set

Up

Down

To increase data (setting parameters)

To decrease data (setting parameters)

Run

Run

To start softstarter

Stop/reset

Stop or reset

To stop softstarter

To reset in fault status

2.3 Parameters Setting

User can modify to effect different modes of operation control

Steps

1

2

3

4

OUT

SST

Keys

Fun or

Set or

5 set

Panel display

Items

-HF-

RUN

STOP

Operation

Press “Fun” key to display function code

Press “Up” or “Down” to select required function code

To read data set in the function code

To modify data

Finish setting and display present function code

Display

HF01

HF09

150

350

HF09

DEL_

PC、OC1、OC2、

OL、OH、PF

10

Remarks

Reset status

Startup status

Stop status

By pass running status

Soft stop status

Startup interval status(During startup interval to operate the displayed item)

PC protect, Startup over current 1, Startup over current 2,

Startup over load, over heating and out phase.

Remain time of delay startup

·6·

III

Functional Block Diagram

3.1 Functional Block Diagram

HFR1000

Three reverse-parallel connection SCR modules are adopted as power element. By picking up synchronization signal from input voltage sampling, it can pick up output current sampling for feedback fuzzy control, trace the phase automatically and control phase displacement angle. Voltage can thus be increased step by step, and startup current will be under control. After startup, the bypass contactor will make the SCR short circuit. The motor will finally be driven into the electricity network for operation.

·7·

HFR1000

IV Installation & Connection

4.1 Power loop wiring

Model

HFR1015

HFR1022

HFR1030

Matched

Motor

15

22

30

Rated

Current

30

45

60

Lead Section

Area(mm

2

)

16

16

25

By Pass Contactor Rated

Current (Recommended)

35A

50A

65A

HFR1037

HFR1045

HFR1055

HFR1075

HFR1090

HFR1110

37

45

55

75

90

110

75

90

110

150

180

220

25

35

35

50

70

70

80A

100A

120A

165A

190A

250A

HFR1132

HFR1160

HFR1220

HFR1250

HFR1280

HFR1315

132

160

220

250

280

315

260

320

440

500

560

630

95

120

185

240

240

150*2

280A

350A

500A

500A

600A

630A

Remarks:

1. The rated current value of the by pass contactor selected must be higher than the recommending value.

2. The capacity of by pass output relay of the softstarter is 7A/250AC, when the by pass contactor‟s loops current is higher than this capacity then add up a middle relay is recommended.

·8·

4.2 Wiring Recommended

HFR1000

R, S, T terminals of softstarter are input terminals while U, V and W are output terminals.

QF is auto air breaker, KM is contactor, RJ is over heating protection relay, RD1 is fuse,

L11is N connected to 230V. And L11-N is forbidden being connecting to 400V.

! PE Grounding wire should be as short as possible, and should be connected to the nearest grounding point, better on the installation board against the soft starter.

Installation board should also be grounded.

! Please connect motor with the phase-sequence recommended by manual. Correctly connect softstarter output with bypass contactor. Otherwise softstarter and motor will be ruined.

·9·

HFR1000

4.3 Terminal Function

Y1 Y2 Y3 T1 T2 T3 30A 30B 30C CM RUN STOP BX RST PE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Terminal

Number

Terminal Name Description Technical Parameters

Y1

Y2

Y3

T1

Delay Start Terminal

When delaying start:Y2-Y1 opened,

Y3-Y1 closed, the contacts of relay will be reversed after delay start

After startup:T2-T1 open,T3-T1

Capacity:7A/250

VAC

Y1:middle end

Y2-Y1 normally closed

Y3-Y1 normally opened

Capacity:7A/250

VAC

T2

T3

By pass Contactor

Terminal closed, for turnover to by pass contactor or middle relay after startup

T1:middle end

T2-T1 normally closed

T3-T1 normally opened

30A

30B

30C

Fault Output

Terminal

During fault:30B-30A open

30C-30A close,for fault output

Capacity:7A/250VAC

30A:middle terminal

30B-30A normal close

30C-30Anormal open

RUN Startup Terminal RUN-CM close for startup status

STOP

BX

Stop Terminal

Free Stop Terminal

STOP-CM close for stop status

BX-CM close for free stop status

RST

CM

PE

Reset Terminal

Common Terminal

Ground Terminal

RST-CM close for reset status

CM (External control common terminal)

PE connect with ground

·10·

HFR1000

V Function Parameters

5.1 Parameters List

Function No. Function Explanation

HF00 Control mode

HF01

HF02

HF03

HF04

HF05

HF06

HF07

HF08

HF09

HF10

HF11

Startup mode

Startup delay time

Stop mode

Torque compensation

Kick voltage

Kick time

Ramp ascending time

Ramp descending time

Startup current limit

Startup time interval

Reverting to Mfr‟s Value

Data Explanation

0 Keypad control

1 External terminal control

2 Keypad + terminal control

3 Modbus

4 Keypad+terminal+Modbus

0 Voltage ramp startup

1 Current limit startup

2 Kick startup

0-600S

Mfr Value

2

1

0S

0 Free stop 1 Soft stop 0

0-50% rated voltage

20-80% rated voltage

5%

50%

1-60S

1-120S

1-60S

150-400% rated current

1-3600S

0 No action

1 Action (manufacturer value restored)

The latest fault

2S

20S (15-30kw)

60S (37-75kw)

100S (90-315kw)

2S

300%

240S

0

0 HF12 Fault memory 1

HF13 Fault memory 2

HF14 Fault memory 3

HF15 Reserved

HF16 PC protection selection

The last but one fault

The latest fault current

0 Invalid 1 Valid

HF17 Voltage ramp OL coefficient 0-60

HF18 Out phase selection 0 Invalid 1 Valid

0

0

Mfr‟s Value

1

0

1

·11·

HFR1000

HF19 Parity check 0 No check 1 Odd 2 Even 0

HF20 Communication baud rate 0: 1200 1: 2400 2: 4800 2

HF21 Communication Address

3: 9600 4: 19200

1-127: Softstarter address

HF22 Selection of ASCII mode and 0 ASCII mode

RTU mode 1 RTU mode

1

0

HF23 Softstarter power

HF24 Close loop Control mode

HF30 Software Edition No.

15-315KW

0 Close loop mode 1

1 Close loop mode 2

Subject to model

0

Mfr‟s value

HF25-HF29, Reserved (Do not change) Mfr‟s value

HF31

5.2 Parameters Instruction

HF00 Control mode

0 Keypad control

1 External terminal control

2 Keypad + terminal control

3 Modbus

2

4 Keypad+terminal+Modbus

Control mode selection can be operated directly through the panel keypad, and the manufacturer value is 2.

“Keypad control” refers to the start/stop commands given by the “Run” or “stop/reset” key on the keypad.

“Terminal control” refers to the start/stop command given by the “Run” and “Stop” terminals.

When HF00=3, the running command is given by Modbus.

When HF00=4, keypad + terminal + Modbus command are valid at the mean time.

HF01 Startup mode 0 Voltage ramp startup 1

1 Current limit startup

2 Kick startup

You can start by selecting one of the following three modes:

0 Voltage ramp startup, 1 current limit startup, 2 kick startup, manufacturer value is 1

Δ

Voltage ramp startup

Set HF01 to 0, and set ramp startup time t (HF07) and torque compensation voltage

(HF04) U0, the motor will start along with the increasing input voltage, and the speed will accelerate accordingly till its top speed, as shown in Fig1.

·12·

HFR1000

U

Ue

U0 t (HF07) T

Fig1 Voltage Ramp Startup Feature Curve

Δ

Current limit startup

Set HF01 to 1 and set startup current limit percent Is(HF09)and Torque compensation voltage (HF04). The current of the motor will increase until the voltage ramp reaches Is, then it will stop, and the speed will accelerate to its full speed. After that, the current will decrease to below the rated current Ie, as shown in Fig2:

I

Is

Ie

T

Fig2 Current Limit Startup Feature Curve

Δ

Kick startup

Set HF01 to 2, and set ramp start time t (HF07) and torque compensation (HF04), kick time t(HF06). The motor will start rapidly along with the increasing voltage, then the voltage will increase in a ramp way, and the speed will accelerate to its full speed. It is better for startup motor with big inertia, as shown in Fig3:

·13·

HFR1000

U

Ue

Us

U0

t(HF06)

T

Fig3 Kick Startup Feature Curve

HF02 Startup delay time 0-600 0S

Startup delay time is set for startup preparation, and the motor will not start in this interval. Count down mode is used for display, and the time can be set from 0 to 600 seconds. When start delay, Y2-Y1 open, Y3-Y1 close, Use these two contacts can output a warning signal. The manufacturer value is set to 0S

HF03 Free stop 0 Free stop 1 Soft stop 0

Free stop means that the voltage of softstarter will reduce directly from Ue to 0V,and the motor will run with inertia till its stop, as shown in Fig4:

U

Ue

T

Fig4 Free Stop Feature Curve

Soft stop means that the voltage of starter will reduce gradually from Ue to 0V when the voltage drops. The soft stop can help resist “water hammer domino effect ”, as shown in

Fig5:

·14·

HFR1000

U

Ue

HF04

t(HF08) T

Fig5 Soft Stop Feature Curve

Torque compensation 0-50% rated voltage 5%

Torque compensation means to adjust the torque produced by initial voltage U0. The manufacturer value is set to 5%. If the load is heavy, please increase HF04. It is valid in voltage ramp startup and current limit startup. Please note that big value‟s setting is not recommended, increase gradually the value.

HF05 Kick voltage 20-80% rated voltage 50%

As for a load with big static torque, an instant high voltage must be inflicted, so that it can start smoothly with the torque big enough, the “kick voltage” range is from 20% to 80% percent of the rated voltage. The manufacturer value is set to 50% rated voltage. Please note that big value‟s setting is not recommended, increase gradually the value.

HF06 Kick time 1-60S 2S

Kick time means the interval to exert high voltage, adjustable between 1-60S. The manufacturer value is set to 2S.

HF07 Ramp ascending time 1-120S 20S (15-30kw)

60S (37-75kw)

100S (90-315kw)

Ramp ascending time means the interval to bring the voltage from 0V up to rated voltage

Ue.

HF08 Ramp descending time 1-60S 2S

Ramp descending time means the interval to bring the voltage from rated voltage Ue to

0V. The manufacturer value is set to 2S.

HF09 Startup current limit 150-400% rated current 300%

·15·

HFR1000

It works when HF01 is set to 1, startup current limit = HF09*Ie, please adjust HF09 for a successful start, less current is preferred. Please note that big value‟s setting is not recommended, increase gradually the value.

HF10 Startup interval 1-3600S 240S

This equipment is small-sized, and you can only restart it when the radiator cools down from the previous startup, otherwise the machine will stop due to over-heating protection.

The startup interval is adjustable, and no more than 10 startups per hour are preferred for full load startups. The manufacturer value is set to 240S.

HF11

Reverting to

Mfr‟s value

0 no action

1 action (manufacturer value is restored)

0

When the data is in disorder, please restore the manufacturer value by setting data initialization 1.

0

0

HF12

HF13

Fault memory 1

Fault memory 2

The latest fault

The last but one fault

Store and display the code of the last but two fault:

Fault Code Fault Details

0

1

2

No Fault

OH Overheating Fault

OC Over current Fault

3

4

PF Out phase Fault

OL Over load or jam Fault

HF14 Fault memory 3

The latest fault current is stored in HF14.

The latest fault current

HF15 Reserved

0

Mfr‟s value

It‟s a reserved parameter and user no need to setup.

HF16 PC protection selection 0 invalid 1 valid 1

When HF16 is set to 1, the function is valid. It is used to protect the setting of motor and softstarter.

HF17 Voltage ramp OL coefficient 0-60 0

Set overload time protection coefficient in the voltage ramp startup. When OL malfunction occurs in the voltage ramp startup, please increase this parameter.

·16·

HFR1000

HF18 Out phase selection 0 invalid 1 valid 1

HF18 is out phase selection, 0 means out phase function is invalid, 1 means this function is valid, Mfr‟s value is 1.

HF19 Parity check 0 No check 1 Odd 2 Even

Set the mode of Parity check. The manufacturer value is set to No check.

HF20 Communication baud rate 0: 1200 1: 2400

2: 4800 3: 9600

4: 19200

Set the communication baud rate. The manufacturer value is 4800.

0

2

HF21 Communication Address 1-127: Softstarter address

Set softstarter address. The manufacturer value is 1.

1

HF22 Selection of ASCII mode and RTU mode

0 ASCII mode

1 RTU mode

Set communication mode. The manufacturer value is set to ASCII mode.

0

HF23 Softstarter power 15-315KW

Subject to model

Motor power setting is applied for current display warp revising and setting current limited value. The manufacturer value is subject to model.

HF24

Close loop Control mode

0 Close loop mode 1

1 Close loop mode 2

0

Set 0 means close loop mode 1, set 1 means close loop mode 2. The manufacturer value is

0, the close loop mode 1 is fit for most loads, but centrifugal fan or other big inertia load will cause the unsteady starting. The close loop mode 2 is recommended for this situation.

HF30 Software Edition No. Mfr‟s value

HF30 will display the Edition No. of software. User can only check it.

HF25-HF29, Reserved (Do not

HF31 change)

Mfr‟s value

·17·

HFR1000

VI. External Dimension and Mounting Size

Unit:mm

Model

HFR1015

HFR1022

HFR1030

HFR1037

HFR1045

HFR1055

HFR1075

HFR1090

HFR1110

HFR1132

HFR1160

HFR1220

HFR1250

HFR1280

External Dimension

(A×B×H)

153×162×250

153×162×250

153×162×250

153×162×250

153×162×250

153×162×250

260×194×510

260×194×510

260×194×510

260×194×510

260×194×510

360×255×590

360×255×590

360×255×590

HFR1315 360×255×590

Installation of copper platoon

Structure Code

Mounting Size

(W×L)

140×219

140×219

140×219

140×219

140×219

140×219

232.5×389

232.5×389

232.5×389

232.5×389

232.5×389

300×560

300×560

300×560

300×560

L1*L2*L3

M5

M8

M8

M8

M5

M5

M5

M5

M5

M8

M8

M8

M8

M8

M8

R2

R3

25 X 480 X 70

34 X 550 X 101

·18·

Metal

Hanging

Type

R1

R2

R2

R2

R1

R1

R1

R1

R1

R2

R2

R3

R3

R3

R3

Remarks

Plastic

Hanging

Type

HFR1000

Structure Diagram:

R1 Structure R2 Structure

R S T

U V W

R3 Structure

Copper platoon structure diagram

R S T

U V

For R2 For R3

W

·19·

HFR1000

. Appendix

Appendix 1. Trouble Shooting of Keypad Panel Display

Protection function

Display in the panel

Over current OC1/OC2

Out phase

Overheat

Over load

PC protection

P.F.

OH

OL

PC

Counter measures

*Please decrease HF04 and increase HF07 in the voltage ramp startup.

*Please refer to Appendix 2 in the current limited startup.

*Please check if power input is normal.

*If the fault caused by power supply, please set

HF18=0, Out phase function is invalid.

*Please check softstarter installation environment and improve ventilation;

*Please decrease startup times if startup is frequent.

*When the temperature fell into the safe range, OH protection stops.

*Please increase HF17 and HF07 in the voltage ramp startup

*Please increase HF09 in the current limited startup.

*If softstarter is switched into bypass within 1S during the starting process, “PC” malfunction will display.

Please increase HF07 and decrease HF09. If softstarter runs alone without load, “PC” malfunction will display.

*If the power of motor and softstarter has a great difference, “PC” will display because starting process is too fast. Please match the right power of softstarter.

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HFR1000

Appendix 2. Fault Diagnosis

Problems

Motor sounds buzz, when power is on

Motor can not work normally with the startup signal input.

Status explanation

Soft starter is in standby state

Standby status is displayed in the panel

Trouble shooting

1. Check whether the bypass contactor is blocked at the closed place;

2. Check whether the silicon controlled rectifier

(SCR) is spark-through or damaged.

1. In external control state, check whether the terminal RUN-CM is turned on;

2. Check whether the control circuit connection is right, control switch works normally.

No control power supply state

1. Check whether voltage is normal.

Wrong parameter set

1. Check every parameter set value one by one, make sure that the set values match the practical parameters of motor;

2. Check the current limit value

Phase loss occurs during startup

Check three phases‟ voltage, judge whether there is phase loss and eliminate fault

Startup current exceeds the set value

Wire connection of motor is open

Current limit function fails

Environment temperature is too high

Over run current of motor

1. Check whether the connection of output terminals of soft starter and what of motor is right and reliable;

2. Check the input terminals‟ voltage, judge whether internal circuit of motor is open;

3. Check whether there is phase loss in input terminal

1. Check whether the startup current set is right;

2. Check whether the connection of current mutual inductor is right;

3. Check whether the current mutual inductor works properly, and matches the motor.

1. Check whether soft starter installation environment has good ventilation and is installed vertically;

2. Check whether soft starter avoids direct sunlight successfully;

1. Check whether the soft starter has short circuit in output connection ;

2. Check whether overload of motor or damage

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HFR1000

Soft starter is short circuit between input and output terminal connection happens;

3. Check whether phase loss fault happens in the motor.

1.Check whether the bypass contactor is blocked at the closed place;

2.Check whether the silicon controlled rectifier

(SCR) is sparked through or damaged

The above problems must be handled by professionals. Users are not allowed for any repair by themselves.

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HFR1000

Appendix 3. Applications (for reference)

Machinery type

Load type

Startup mode

Voltage

Ramp

Current limited

Parameters setting

Torque

(%)

Current

(%)

10% 300%

Startup time

S

10 30

Fan compressor

(piston-type) compressor

(centrifugal)

Convey

A little heave load

Standard load

Standard load

Standard load

Mixer

A little heave load

Ball crusher Heavy load

20%

10%

15%

10%

15%

30%

350%

300%

350%

10 30

10 30

10 30

10 30

20

40

30 60

Muller Heavy load ● 30% 400% 30 60

Users can set the parameters according to actual load.

To a little heavy load and heavy load, the manufacturer recommend user to choose higher power of softstarter. For example: centrifugal fan, mixer, ball crusher and muller. If the load starts frequently (ten times with one hour), please choose higher power of softstarter. Furthermore, the startup mode of “Kick startup” is recommended for heavy load and heavy inertia.

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HFR1000

Appendix 4 Communication Manual

(Modbus Version 1.5)

I. General

Modbus is a serial and asynchronous communication protocol. Modbus protocol is a general language applied to PLC and other controlling units. This protocol has defined an information structure which can be identified and used by a controlling unit regardless of whatever network they are transmitted.

Modbus protocol does not require a special interface while a typical physical interface is

RS485.

You can read reference books or ask for the details of MODBUS from manufactures.

II. Modbus Protocol

1. Overall Description

(1) Transmission mode

1) ASCII Mode

When controllers are setup to communicate on a Modbus network using ASCII mode, each 8–bit byte in a message is sent as two ASCII characters. For example, 31H

(hexadecimal data) include two ASCII characters‟3(33H)‟,‟1(31H)‟.

Common characters, ASCII characters are shown in the following table:

Characters

„0‟ „1‟ „2‟ „3‟ „4‟ „5‟ „6‟ „7‟

ASCII Code 30H 31H

Characters

„8‟

„9‟

32H

„A‟

33H 34H 35H

„B‟ „C‟ „D‟

36H 37H

„E‟ „F‟

ASCII Code 38H 39H 41H 42H 43H 44H 45H 46H

2) RTU Mode

In RTU mode, one Byte is expressed by hexadecimal format. For example, 31H is delivered to data packet.

(2) Baud rate

Setting range: 1200, 2400, 4800, 9600, 19200

(3) Frame structure:

1) ASCII mode

Byte

1

7

0/1

1/2

Function

Start Bit (Low Level)

Data Bit

Parity Check Bit (None for this bit in case of no checking. Otherwise 1 bit)

Stop Bit (1 bit in case of checking, otherwise 2 bits)

2) RTU mode

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HFR1000

Byte Function

1

8

Start Bit (Low Level)

Data Bit

0/1

1/2

Parity Check Bit (None for this bit in case of no checking. Otherwise 1 bit)

Stop Bit (1 bit in case of checking, otherwise 2 bits)

(4) Error Check

1) ASCII mode

Longitudinal Redundancy Check (LRC): It is performed on the ASCII message field contents excluding the „colon‟ character that begins the message, and excluding the

CRLF pair at the end of the message.

The LRC is calculated by adding together successive 8–bit bytes of the message, discarding any carries, and then two‟s complementing the result.

A procedure for generating an LRC is:

1. Add all bytes in the message, excluding the starting „colon‟ and ending CRLF. Add them into an 8–bit field, so that carries will be discarded.

2. Subtract the final field value from FF hex (all 1‟s), to produce the ones–complement.

3. Add 1 to produce the twos–complement.

2) RTU Mode

Cyclical Redundancy Check (CRC): The CRC field is two bytes, containing a 16–bit binary value.

The CRC is started by first preloading a 16–bit register to all 1‟s. Then a process begins of applying successive 8–bit bytes of the message to the current contents of the register. Only the eight bits of data in each character are used for generating the CRC. Start and stop bits, and the parity bit, do not apply to the CRC.

A procedure for generating a CRC-16 is:

1. Load a 16–bit register with FFFF hex (all 1‟s). Call this the CRC register.

2. Exclusive OR the first 8–bit byte of the message with the high–order byte of the

16–bit CRC register, putting the result in the CRC register.

3. Shift the CRC register one bit to the right (toward the LSB), zero–filling the MSB.

Extract and examine the LSB.

4. (If the LSB was 0): Repeat Step 3 (another shift).

(If the LSB was 1): Exclusive OR the CRC register with the polynomial value A001 hex

(1010 0000 0000 0001).

5. Repeat Steps 3 and 4 until 8 shifts have been performed. When this is done, a complete 8–bit byte will have been processed.

When the CRC is appended to the message, the low-order byte is appended first, followed by the high-order byte.

2. Command Type & Format

(1) The listing below shows the function codes. code name

03 Read Holding

Registers description

Read the binary contents of holding registers in the slave. (Less than 10 registers once time )

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HFR1000

06 Preset Single

Register

(2) Format

1) ASCII mode

Start Address Function

:

(0X3A)

Softstarter

Address

Function

Code

Preset a value into holding register

Data

Length

Data

Data

1

Data

N

LRC check

High-order byte of LRC

Low-order byte of LRC

2)RTU mode

Return

(0X0D)

End

Line Feed

(0X0A)

Start

T1-T2-T3-T4

Address Function Data

Softstarter

Address

3) Protocol Converter

Function

Code

N data

CRC check

Low-order byte of CRC

High-order byte of CRC

End

T1-T2-T3-T4

It is easy to turn a RTU command into an ASCII command followed by the lists:

1) Use the LRC replacing the CRC.

2) Transform each byte in RTU command into a corresponding two byte ASCII. For example: transform 0x03 into 0x30, 0x33 (ASCII code for 0 and ASCII code for 3).

3) Add a „colon‟ ( : ) character (ASCII 3A hex) at the beginning of the message.

4) End with a „carriage return – line feed‟ (CRLF) pair (ASCII 0D and 0A hex).

So we will introduce RTU Mode in followed part. If you use ASCII mode, you can use the up lists to convert.

(3) Address and meaning

The part introduces softstarter running, softstarter status and related parameters setting.

Description of rules of function codes parameters address:

1) Use the function code as parameter address

1. General Series:

High-order byte: 01~09 (hexadecimal)

Low-order byte: 00~3C

For example: F114 (display on the board), parameter address is 010E (hexadecimal).

2. Softstarter series

High-order byte: 00

Low-order byte: 00~3C

For example: HF14 (display on the board), parameter address is 000E (hexadecimal).

Note: in this situation, it allows to read six function codes and write only one function code.

Some function codes can only be checked but cannot be modified; some function codes can neither be checked nor be modified; some function codes can not be modified in run state; some function codes can not be modified both in stop and run state.

In case parameters of all function codes are changed, the effective range, unit and related instructions shall refer to user manual of related series of softstarters. Otherwise, unexpected results may occur.

2) Use different parameters as parameter address

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HFR1000

(The above address and parameters descriptions are in hexadecimal format, for example, the decimal digit 4096 is represented by hexadecimal 1000).

1. Running status parameters

Parameters Address

1001

1002

2. Control commands

Parameter Descriptionread only

The following is softstarter status.

The high-order byte is 0, and low-order byte is the status of softstarter.

0. standby

1. running

2. OC2 protection

3. OC1 protection

4. PF protection

5. OH protection

6. OL protection

Output current

Parameters Address

2000

Parameters Descriptionwrite only

Command meaning:

0003Deceleration stop

0004Free stop

0008Runno directions

0009Fault reset

3. Communication parameters

Parameters Address

2001

Parameters Descriptionread only

Lock parameters

0001Relieve system locked (remote control locked

0002Lock remote control (any remote control commands are no valid

before unlocking

4. Response

Illegal Response When Reading Parameters

Command Description

Slave parameters response

Function

The highest-order byte changes into 1.

Data

Command meaning:

0001: Illegal function code

0002: Address of illegal data

0003: Illegal data

0004: Slave fault

The following is response command when read/write parameters:

Eg1: In RTU mode, change acc time (F007) to 10.0s in NO.01 softatarter.

Host Query

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HFR1000

Address Function

Register

Address Hi

Register

Address Lo

Preset

Data Hi

CRC Lo CRC Hi

01 06 F0 07 00 0A

Function code F007 Value: 10.0S

Slave Response

8B 0C

Address

01

Function

06

Register

Address Hi

F0

Register

Address Lo

07

Response

Data Hi

00

Response

Data Lo

04

CRC

Lo

0A

CRC Hi

Function code F007 Do not allow to change

C8

Eg 2Read status and output voltage from N0.2 softstarter.

Preset Data

Lo

Host Query

Address Function

First Register

Address Hi

First Register

Address Lo

Register count Hi

02 03 10 00 00

Communication Parameters Address 1000H

Slave Response:

Register count L0

02

CRC Lo CRC Hi

C0 F8

02 03 04 00 02 00 00

OC1 protection output current

Eg 3NO.1 softstarter runs forwardly.

Host Query:

Address Function

Register

Hi

Register

Lo

68

Write status Hi

F3

Write status Lo

CRC Lo CRC Hi

01 06 20 00 00 01 43 CA

Communication parameters address 2000H Forward running

Slave Response:

Address Function

Register

Hi

Register

Lo

Write status Hi

Write status Lo

CRC Lo CRC Hi

CA 01 06 20 00 00

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01

Writing parameters successfully

Eg4: Read the value of F017 from NO.2 softstarter

Host Query:

43

HFR1000

Address Function

02 03

Register

Address Hi

F0

Register

Address Lo

11

Register

Count Hi

00

Register

Count L0

01

CRC

Lo

E7

Communication Parameter Address F011H Reading one Register.

Slave Response:

CRC

Hi

3C

Address Function

Register

Address Hi

Register

Address Lo

Read status

Hi

Read status

Lo

CRC

Lo

CRC

Hi

02 03 F0 11 00 04

The actual value is 4.

3. Additional Remarks

(1)

Expressions during communication course:

Parameter Values of Current=actual value X 10

27 3F

Others parameter Values=actual value X 1

Parameter value is the value sent in the data package. Actual value is the actual value of softstarter. After

PC/PLC receives the parameter value, it will divide the corresponding coefficient to get the actual value.

NOTE: Take no account of radix point of the data in the data package when PC/PLC transmits command to softstarter.. The valid value is range from 0 to 65535.

Function codes related to communication

Function Code

HF18

Name

Stop bit

Setting Rang

0 one bit 1 two bits

Mfr‟s Value

0

HF19

Parity Check 0: No check 1: Odd 2:Even 0

HF20 Baud Rate

0 1200 1 2400

2 4800 3 9600

4 19200

1-127

2

HF21

HF22

Soft starter‟s Address

ASCII and RTU mode

0 ASCII Mode

1 RTU Mode

1

0

Selection

You can read device status and function code value or preset functions value of soft starter regardless of value of HF00.

Please set functions code related to communication consonant with the PLC/PC communication parameters, when soft starter communicate with PLC/PC.

physical interface

1 interface

Hardware uses communication MAX485, the following are the pin of 485 interface.

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HFR1000

VCC:

5V

power supply

GND: ground of 5V

Connect A+ to A+ of PLC or other converter and connect A -to B- of PLC or other Converter, when soft starter communicate to other devices.

2 Structure of Field Bus

PLC/PC

Field Bus

EURA soft starter

EURA soft starter

Connecting Diagram of Field Bus

RS485 Half-duplex communication mode is adopted for EURA softstarter.

Daisy chain the devices together. Do not use 'spur' lines, or a star configuration. Terminating Resistors of

120 Ohms should be used on the ends of long modbus/485 loops. In the first example below, the terminator should be placed at the PLC and modbus device 4.

Correct

Wrong

1

Softstarer

1 2

3 4

Modbus device

soft starter

2

Softstarter

3

4

Modbus device

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HFR1000

Wrong

4

Softstarter

1

2

Modbus device

3

Please note that for the same time in half-duplex connection, only one softstarter can have communication with PC/PLC. Should two or more than two softstarters upload data at the same time, then bus competition will occur, which will not only lead to communication failure, but higher current to certain elements as well.

No direct grounding shall be allowed for any point of RS485 network. All the equipment in the network shall be well grounded via their own grounding terminal. Please note that grounding wires will not form closed loop in any case.

Please think over the drive capacity of PC/PLC and the distance between PC/PLC and softstarter when wiring. Add a repeaters if drive capacity is not enough. Modbus repeaters may be used to extend the length of the loop, but introduce delay in the device response time. Using repeaters on slow devices may cause timeout problems.

All wiring connections for installation shall have to be made when the softstarter is disconnected from power supply.

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