HNC Electric HRS Series User manual

HRS Series High Performance Soft Starter
Operation Manual
V1.0
HNC Electric Limited

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Contents
Operating Instruction Manual(V1.0)........................................................................................................................ - 4 -
Foreword.................................................................................................................................................................. - 5 -
Excellent Performance............................................................................................................................................. - 6 -
Typical Applications ................................................................................................................................................. - 7 -
Use and environmental conditions.......................................................................................................................... - 7 -
Safety Precautions ................................................................................................................................................... - 8 -
1. Overview.............................................................................................................................................................. - 9 -
1.1 Product features ........................................................................................................................................ - 9 -
1.2 Structural features ..................................................................................................................................... - 9 -
1.3 Introduction of product typical applications ........................................................................................... - 10 -
1.4 Use and environmental conditions.......................................................................................................... - 10 -
1.5 Packing list ............................................................................................................................................... - 10 -
1.6 Working principle..................................................................................................................................... - 11 -
1.7 Incoming inspection................................................................................................................................. - 11 -
2. Product Selection............................................................................................................................................... - 12 -
2.1 Product nameplate .................................................................................................................................. - 12 -
2.2 Model and definition ............................................................................................................................... - 12 -
2.3 Precautions for selection ......................................................................................................................... - 12 -
3. Installation........................................................................................................................................................ - 13 -
3.1 Outer dimension of soft starter............................................................................................................... - 13 -
3.2 Requirements of installation.................................................................................................................... - 14 -
4. Wiring............................................................................................................................................................... - 15 -
4.1 Application wiring diagram...................................................................................................................... - 15 -
4.1.1 Main circuit connection diagram of soft starter..................................................................... - 15 -
4.1.2 Configuration diagram of terminals ........................................................................................ - 16 -
4.1.3 Primary and secondary wiring diagram................................................................................. - 17 -
4.1.4 Wiring diagram of relay and remote control.......................................................................... - 18 -
5. Display for Keyboard Interface..................................................................................................................... - 19 -
5.1 Description for displaying the keyboard.................................................................................................. - 19 -
5.2 Buttons..................................................................................................................................................... - 19 -
5.3 Function and parameter table................................................................................................................. - 20 -
5.4 Functions selection and description........................................................................................................ - 22 -
5.5 Parameter modification........................................................................................................................... - 27 -
5.6 Help information and description............................................................................................................ - 27 -
5.7 Protection function and description........................................................................................................ - 27 -
6. FaultsAnalysis................................................................................................................................................ - 29 -
6.1 Overview.................................................................................................................................................. - 29 -
6.2 Common problems and countermeasures .............................................................................................. - 29 -
6.3 Fault codes and solutions ........................................................................................................................ - 30 -
7. MODBUS Communication Protocol............................................................................................................. - 32 -
7.1 Overview about Modbus RTU communication protocol ......................................................................... - 32 -
7.2 Related setting of soft starter.................................................................................................................. - 32 -

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7.3 Abnormal response.................................................................................................................................. - 34 -
7.4 Precautions for use .................................................................................................................................. - 35 -
8. Precautions of Use and Daily Maintenance for HRS................................................................................ - 36 -
8.1 Precautions for application use ............................................................................................................... - 36 -
8.2 Daily maintenance of soft starter ............................................................................................................ - 37 -

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Operating Instruction Manual(V1.0)
◼Please read the instruction manual carefully and understand the contents so as to be able to correctly install, connect
the circuit, operate and maintain, etc..
◼The technical specifications of this product may change without notice.
◼This instruction manual should be kept until the product is scrapped.
◼This instruction manual should be kept in the hands of the actual end user.

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Foreword
Thank you for using HRS Series intelligentAC motor soft starter produced by HNC ELECTRIC LIMITED.
HRS Series soft starter is a intelligent AC motor soft starter with international leading technology newly developed by HNC
ELECTRIC LIMITED. HRS Series soft starter uses power electronic technology, microprocessor technology and modern
control theory technology, and has a new type of starting equipment with the international advanced level. This product
can effectively limit the starting current of asynchronous motors when starting, and can be widely used in heavy-duty
equipment such as fans, water pumps, conveyors, and compressors. It is an ideal replacement product for star/delta
conversion, auto-coupling step-down, magnetic control step-down and other step-down starting equipment.
The HRS Series soft starter not only has the same excellent performance as the international high-end soft starter, but
also combines the application characteristics to further strengthen the reliability of the product, the adaptability of the
environment, and the humanized and industrialized design, which can meet the requirements of various applications.

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Excellent Performance
●Multi-start mode:
The voltage ramp starting mode can obtain the max. output torque, the constant current soft starting mode can obtain the
max. limited starting current, and the sudden jump starting mode can be applied to loads with large static friction during
starting.
●High reliability:
There are high-performance microprocessors for digital processing of the signals in the control system, avoiding excessive
adjustments of the previous analog circuits, thereby obtaining excellent accuracy and execution speed.
●High performance:
Programmable delay start mode, programmable interlock control.
There is no phase sequence requirement for input power.
The starting time and stopping time can be modified digitally.
The dynamic fault memory function makes it easy to find the cause of the fault and can record up to ten faults.
●Full dynamic control monitoring starter of field-bus, easy to network:
The bus type is Modbus.
●With multiple protection functions:
Protects against over-voltage, under-voltage, overheating, phase loss, and motor overload.
●Perfect humanized design:
Harmony of beautiful appearance and reasonable structure.
Harmony of perfect functions and easy operation.
Harmony of firmness, reliability and compact structure.
Artistic design of industrial products excellence.
●Reliable quality assurance:
Using computer simulation design.
STM patch production process.
Excellent electromagnetic compatibility performance.
High temperature aging and vibration test of the entire machine before leaving the factory.
●Fast and thoughtful after-sales service:
Reliable performance and quality lay the foundation for quality service.
Provide excellent and complete equipment design solutions.
Timely and thoughtful use consultation.
Continuously improve product performance based on user’s opinion.

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Typical Applications
●Water pump
Using the soft stop function, the water hammer phenomenon of the pump is relieved when the pump is stopped, and the
cost of system maintenance is saved.
●Ball Mill
Using voltage ramp to start, reduce the wear of gear torque, reduce maintenance workload, save time and save money.
●Fan
Reduce belt wear and mechanical shock, saving maintenance costs.
●Compressor
The use of current limiting realizes smooth starting, reduces motor heating and prolongs service life.
●Crusher
Using locked-rotor protection and fast protection to avoid mechanical failure or blockage causing the motor to overheat
and burn.
●Conveying machinery
Realize a smooth and gradual starting process through soft start, avoid product displacement and liquid overflow.
Use and environmental conditions
●Main circuit power supply: three-phase AC 380V (- 10%, + 15%), 50Hz±0.5%
Note:The above data only applies to this manual
●Control circuit power supply: built-in AC380V 50Hz
●Applicable motor: general squirrel-cage asynchronous motor.
●Starting frequency: It is recommended to start and stop no more than 20 times per hour.
●Cooling method: natural air cooling.
●Installation method: wall-mounted.
●Protection level: IP20 ~ IP30, depending on the power level. below 75kW is IP30, 75kW and above is IP20
●Environmental conditions: If the altitude exceeds 2000 m, the capacity should be reduced accordingly.
Ambient temperature is between-25~ ±40°C.
Relative humidity does not exceed 95% (20C~65C), non-condensing, flammable, explosive, corrosive gas, no
conductive dust.
Install indoors with good ventilation. The vibration is less than 0.5g.

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Safety Precautions

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1. Overview
This soft start controller takes an advanced microprocessor as the core, applies advanced software design methods and
the latest hardware technology, uses thyristor phase shift technology, and realizes the soft start and soft stop functions of
AC asynchronous motors, which has the multiple protection functions such as voltage, under-voltage, over-current,
overload, three-phase unbalance, short circuit, etc.
The soft starter covers 5.5KW~630KW, with reliable quality and good electromagnetic compatibility (EMC). It can be
widely used in heavy-duty equipment such as fans, water pumps, ball mills, crushers, conveyors and compressors. It is an
ideal replacement product for star/delta conversion, auto-coupling step-down, magnetic control step-down and other step-
down starting equipment.
1.1 Product features
⚫Using high-performance single-chip microcomputer and digital logic control technology, it has strong anti-interference
ability.
⚫Starting parameters can be flexibly set according to different loads to obtain the best current curve and best torque
control characteristics.
⚫It provides a smooth and gradual starting process for the motor, reduces the impact of the starting current on the
power grid, reduces the vibration and noise of the equipment, extends the service life of the mechanical transmission
system, and improves the working environment of the workers.
⚫The starting current can be adjusted according to the load to reduce starting loss and generate the best torque with
the minimum current.
⚫There is no phase sequence requirement for input power.
⚫It can be set to free parking and soft parking, and the soft parking time can be adjusted.
⚫With standard RS485 interface and ModBus protocol (order statement).
⚫Using 4 x 8 LCD, parameter modification, easy and intuitive operation.
⚫The product has novel structure, reliable performance, strong function and easy installation and operation.
1.2 Structural features
⚫Soft starter:Natural air cooling, external AC contactor.
⚫Intelligent starting cabinet: Exquisite structure, simple installation.

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1.3 Introduction of product typical applications
⚫The products are widely used in thermal power generation, hydropower, transmission and distribution equipment,
metallurgy, chemical industry, mining, construction and other industries.
⚫Water pump---Using the soft stop function, the water hammer phenomenon of the pump is relieved when the pump is
stopped, and the cost of system maintenance is saved.
⚫Ball mill-Using voltage ramp to start, reduce the wear of gear torque, reduce maintenance workload, save time and
save money.
⚫Fan--Reduce belt wear and mechanical impact, saving maintenance costs.
⚫Compressor---Using current limiting to realize smooth starting, reduces motor heating and prolongs service life.
⚫Belt conveyor---Realize a smooth and gradual starting process through soft start, avoid product displacement and
liquid overflow.
1.4 Use and environmental conditions
Use category: AC-53b
Rated insulation voltage: 660V
Rated impulse withstand voltage: 6KV
Rated limit short-circuit current: 10KA
Rated voltage: 380V±15%, AC three-phase symmetrical power supply;
Frequency: 50Hz/60Hz+2%
Number of starts: 12 times/min
Cooling method:The soft starter is naturally air-cooled, and the fan of the intelligent soft-start cabinet is cooled.
Installation method:Wall-mounted or vertical cabinet
Protection level: IP20 ~ IP30, depending on the power level. below 75kW is IP30, 75kW and above is IP20.
Running height: 1000 meters without capacity reduction (above 1000 m, for every additional 100 m, the current is reduced
by 0.5%)
Ambient temperature:store: -25°C~+70°C
Operating temperature: -5°C~+55°C, above 40°C, the current is reduced by 2% per liter of 1°C
Relative humidity:Max. 90% (temperature is 20°C)
Pollution level: Level III
1.5 Packing list
a. Soft starter；b. User manual；c. Certificate；d. Quality service card。

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1.6 Working principle
The principle block diagram of this soft starter is shown as in Fig. 2. The power part is composed of three pairs of anti-
parallel thyristors as shown in Figure 1. The core microprocessor of the control part collects the synchronization signal,
voltage signal, current signal and motor power factor angle of the power grid. The control software changes according to
these four parameters. Using the thyristor phase shift technology, the voltage applied to the motor slowly reaches the full
voltage according to a certain rule. By setting the control parameters appropriately, the torque and current of the motor can
be better matched with the load requirements.
Fig.1 Thyristor power module Fig.2 principle block diagram
1.7 Incoming inspection
⚫Before taking the soft starter out of its packaging materials, please make sure that the packaging carton has not been
damaged during transportation. Damage to packaging cartons is usually caused by improper transportation. If you
find any damage, please notify the carrier and your dealer representative.
⚫Please confirm that the nameplate and label of the soft starter conform to the packing list and the corresponding
purchase order. If the soft starter is not installed immediately, it should be stored in a clean and dry area with an
ambient temperature of -25°C~+70°C.

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2. Product Selection
2.1 Product nameplate
2.2 Model and definition
2.3 Precautions for selection
The soft starter must provide a force greater than the load resistance moment to complete the start-up. For ordinary loads
such as water pumps, fans, etc., it is recommended to configure soft starters with the same or higher gear specifications,
and for heavy loads such as ball mills, grade 6 fans and crushers, it is recommended to configure soft starters with high or
second gear specifications.

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3. Installation
3.1 Outer dimension of soft starter
①Structure and dimension of product for HRS Series 5.5KW-55KW
Model
Rated
power
(kw)
Rated
current
(A)
Outer dimension(mm)
Installation dimension(mm)
Gross
weight
（kg）
W1
H1
D
W2
H2
d
HRS-5R5-B-G3
5.5
11
146
272
160
133
247
M6
4.0
HRS-7R5-B-G3
7.5
15
146
272
160
133
247
M6
4.0
HRS-011-B-G3
11
23
146
272
160
133
247
M6
4.0
HRS-015-B-G3
15
30
146
272
160
133
247
M6
4.0
HRS-018-B-G3
18.5
37
146
272
160
133
247
M6
4.0
HRS-022-B-G3
22
45
146
272
160
133
247
M6
4.0
HRS-030-B-G3
30
60
146
272
160
133
247
M6
4.0
HRS-037-B-G3
37
75
146
272
160
133
247
M6
4.0
HRS-045-B-G3
45
90
146
272
160
133
247
M6
4.0
HRS-055-B-G3
55
110
146
272
160
133
247
M6
4.0

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②Structural dimension of product for HRS Series 75KW or more
Model
Rated
power (kw)
Rated
current
(A)
Outer dimension(mm)
Installation dimension(mm)
Gross
weight(kg)
W1
H1
D
W2
H2
d
HRS-075-B-G3
75
150
260
435
200
225
360
M8
20
HRS-090-B-G3
90
180
260
435
200
225
360
M8
20
HRS-115-B-G3
115
230
260
435
200
225
360
M8
20
HRS-132-B-G3
132
260
260
435
200
225
360
M8
20
HRS-160-B-G3
160
320
260
435
200
225
360
M8
20
HRS-185-B-G3
185
370
260
435
200
225
360
M8
20
HRS-200-B-G3
200
400
260
435
200
225
360
M8
20
HRS-220-B-G3
220
440
260
435
200
225
360
M8
20
HRS-250-B-G3
250
500
290
460
200
255
390
M8
30
HRS-280-B-G3
280
560
290
460
200
255
390
M8
30
HRS-320-B-G3
320
640
290
460
200
255
390
M8
30
HRS-400-B-G3
400
800
330
485
200
295
405
M8
36
HRS-450-B-G3
450
900
330
485
200
295
405
M8
36
HRS-500-B-G3
500
1000
330
485
200
295
405
M8
36
HRS-630-B-G3
630
1200
410
550
230
375
470
M8
56
3.2 Requirements of installation
Direction of installation
①The soft starter must be installed in the vertical direction, not upside down, it should be installed on a firm structure with
screws.
②The soft starter must generate heat when it is running. To ensure the passage of flowing air, The design leaves a certain
amount of space. The generated heat is dissipated upwards, so do not install under heat-sensitive equipment.
③The main circuit uses top in and bottom out, and the wire should ensure sufficient carrying capacity of current.

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4. Wiring
4.1 Application wiring diagram
4.1.1 Main circuit connection diagram of soft starter

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4.1.2 Configuration diagram of terminals
(1) Terminal diagram of main circuit
5.5kW-55Kw 75kW-630kW
(2) Terminal diagram of control circuit
(3)Terminal wiring of control circuit

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4.1.3 Primary and secondary wiring diagram

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4.1.4 Wiring diagram of relay and remote control

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5. Display for Keyboard Interface
5.1 Description for displaying the keyboard
5.2 Buttons
Button name
Description of functions
1. In the ready state, press [YES] to enter the help menu, and then press[YES] to exit. You
can also press [Stop Reset] to exit.
2. In the setting state, press [YES] to save the new data and exit the setting state.
1. In the ready state, press the [SET] button to enter the function parameter menu and display
"FX: XXX"; at this time, press the [▲] ([▼]) button to display the next (previous) parameter
value.
2. Press the [SET] button again to enter the setting state. At this time, the colon is flashing.
Then you can press [▲][▼] button to modify the parameter value after the colon. Press[YES]
when the colon is flashing. If the data has been modified, it will display: "Data storage
completed", and it will beep twice, indicating that the new data has been saved, and then exit.
If you don't want to save the new data, press the [Set] button, the colon stops flashing and
restore the original data, and then press the[YES] button to exit. You can also press [Stop,] to
exit directly.

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Button name
Description of functions
1. In the setting menu, when the colon is not flashing, press [▲], [▼] button to change the
function number; when the colon is flashing, press [▲], [▼] button to change the data, press
and hold[▲],[▼]button for more than 1 second, the data will be increased or decreased in
rapid succession.
2. Press [▲], [▼] button in the help menu to change the content of the corresponding help
prompt information. In bypass operation, and the setting and help menu is not entered, the
motor running current is displayed. Press the [▲], [▼] button at this time to select and display
the inspecting power of the motor or the thermal balance coefficient of the motor overload.
When the indicated value of the thermal balance coefficient is greater than 100%, overload
protection will be performed.
The motor can be started only when the setting keyboard of function parameter FB is valid,
otherwise, the button cannot start the motor
When the setting keyboard of function parameter FB is valid, the keyboard can be stopped.
Otherwise, the machine can not be shut down by pressing this button, and the function is
"Reset" in the fault state.
5.3 Function and parameter table
Function code
Name
Setting range
Factory
value
Description
F0
Starting voltage
30-80%
30%
Voltage ramp mode is valid;
Starting voltage of current mode is 40%
F1
Soft starting time
02-60S
16S
Voltage mode is valid
F2
Soft stopping time
00-60S
2S
Free stop when set to 0
F3
Starting over-current
Protection time
00-60S
00S
During starting the motor, when the time of more
than 3 times the rated current exceeds the setting
value of this parameter, the over-current
protection will be activated
F4
Programming delay
00-999S
00S
For programmable relay output
F5
Starting current limit
50-500%
280%
Current limiting mode is valid;
The max. current limit in voltage ramp mode is
400%
F6
Max. working current
50-200%
100%
Relative to the value of rated current FP