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.

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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.
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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.
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01 Semiconductors with relay bypass 02 Equivalent circuit diagram 2
∆∇
▶
↑Contact energized
M
3 ~
L1 L2 L3
I1
I2
I3
V1 V2
K3 K3 K2
K1 K1 K2
▶ ▶
↑ ↑
↑
↑
∆∇
M
3 ~
L1 L2 L3
I1
I2
∆∇∆∇
I3
V1 V2
K3 K3 K2
K1 K1 K2
▶
▶ ▶
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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.
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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.
M
3 ~
L1 L2 L3
I1
I2
∆∇∆∇
I3
V1 V2
K3 K3 K2
K1 K1 K2
↑Contact energized
↑ ↑ ↑
↑
M
3 ~
L1 L2 L3
I1
I2
∆∇∆∇
I3
V1 V2
K3 K2
K1 K1 K2
↑Contact energized
↑ ↑ ↑
↑
↑
K3
↑
▶
▶ ▶
▶
▶ ▶
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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
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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.
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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
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