FCMAplus / HFSRplus • Harmonics-Free Motor Starting

Reactor-Based Soft Starters
for LV & MV Motors

Reduce voltage dips, starting current stress, and mechanical wear during motor starting—without injecting harmonics into your power system. Ideal for pumps, compressors, fans, blowers and heavy-duty industrial loads.

iEngineering supplies LV HV reactor-based soft starters (FCMA type) up to 20 MW, 13.8 kV, for 50/60 Hz systems—engineered to meet AS/NZS 60076-6 / IEC 60076-6 requirements.

Explore LV & MV Models Submit Soft Starter Enquiry
Voltage Range
415V–13.8kV
Motor Range
Up to 20 MW
Power Quality
No Harmonics
Reactor-based soft starter panel and motor control installation

Rugged, Reliable & Harsh-Environment Ready

Reactor-based technology avoids power-electronics failure modes, reduces maintenance burden, and can operate reliably in industrial environments without dedicated cooling.

Why soft starters?

Protect Motors, Cables & Power Systems During Starting

Reactor-based soft starters help reduce heating caused by frequent start/stops, reduce mechanical stress on the motor and shaft, and reduce electro-dynamic stresses on cables—extending overall equipment life.

  • Lower starting current and voltage dip
  • Reduced mechanical stress & torque shock
  • Harmonics-free starting (amplitude control, not waveform chopping)
  • Reliable in harsh conditions (reduced dependency on cooling)

Common issues with conventional electronic soft starters

Thyristor / IGBT damage
Overheating & fault trips
Repeated start problems
Unstable starting current

Comparison

Electronic Soft Starter vs FCMAplus / HFSRplus

A quick technical comparison for selection decisions—starting current, harmonics impact, reliability, and lifecycle cost.

Parameter Electronic Soft Starter FCMAplus / HFSRplus (Reactor-Based)
Principle Waveform chopping using thyristors/IGBT/MOSFET Reduced voltage by reactor (potential divider) — amplitude control
Starting current Typically ~3.5–4× FLC Typically ~3–3.5× FLC; can be reduced to ~1–1.5× FLC with Dynamic Compensator
Harmonics Generates harmonics (power quality impact) Harmonics-free (fundamental frequency current)
Maintenance Electronics obsolescence & costly spares Rugged design — no routine maintenance, no obsolescence
Reliability Power components can fail; cooling dependency High reliability; suitable for harsh environments
Cost positioning More cost-effective for LV in many cases Highly competitive for MV (3.3kV / 6.6kV / 11kV); lower installation cost in many projects
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LV & MV Solutions

Soft Starter Models & Options

We design customized solutions specific to each motor by analysing torque-speed curves, current-speed behavior, and moment of inertia—then selecting reactor design and taps to meet performance commitments.

Low Voltage

LV FCMAplus Soft Starter

Air-core series reactor solution for LV motors. Available with bypass contactor/ACB (customer preferred make), and optional full motor feeder package (ACB/contactor, protection relays, metering).

415V / 690V Up to 2,000 kW
Medium Voltage

MV FCMAplus Soft Starter

MV air-core reactor soft starter with bypass vacuum contactor or VCB. Line-side designs available—preferred for hazardous areas or where a neutral terminal box is not available.

3.3kV–13.8kV 200 kW–20 MW
Option

Dynamic Compensator (Low-Current Start)

When ultra-low starting current is required, we can reduce starting current down to ~1–1.5× FLC with a Dynamic Compensator—useful for weak grids, generator supplies, or stringent voltage drop limits.

Low dip start Grid & gensets
Controls

PLC + HMI Automation (Closed-Loop)

Closed-loop control using PLC with HMI for high reliability and repeatable starting performance. Interlocks and protections tailored to your MCC/switchroom standards.

Reliable starts Operator-friendly
Design

5-Tap Reactor Design

Five tap variations with ~5% voltage difference per tap help accommodate motor tolerances and operating conditions, improving selection flexibility and reducing bypass current.

Flexible tuning Better outcomes
Assurance

Impedance Measurement & Commitments

We measure reactor impedance to validate predicted starting current and ensure your project achieves the committed performance on site.

QA focused Measured results

Technical specifications

LV & MV Soft Starter Specifications

Standard spec ranges shown below. Final design is customized to motor, load, starting duty, and site constraints.

LV FCMAplus Soft Starter

Input Voltage415V / 690V
Motor Power RangeUp to 2,000 kW
ApplicationPump, Compressor, Fan, Blower
Frequency50Hz / 60Hz
Operating Temp0°C to 55°C
InstallationIndoor
CoolingAir cooled
Insulation ClassClass F (or customized)
StandardIEC 60076-6 / AS/NZS aligned
ConstructionAir core, VPI epoxy impregnated
ConductorElectrolytic copper
Starting Current3–3.5× FLC (typical); 1–1.5× FLC with Dynamic Compensator
Reactor Variation5-tap (≈5% voltage difference per tap)

What you get

  • Bypass contactor or ACB (preferred make)
  • Optional feeder package (switching, protection, metering)
  • PLC + HMI automation for consistent starts
  • Design based on motor/load curves and inertia

Best for

  • LV motors in process plants & utilities
  • Pumps / compressors / fans / blowers
  • Sites needing low voltage dip and stable starts

MV FCMAplus Soft Starter

Input Voltage3.3 kV to 13.8 kV
Motor Power Range200 kW to 20 MW
ApplicationPump, Compressor, Fan, Blower (and heavy-duty loads)
Frequency50Hz / 60Hz
Operating Temp0°C to 55°C
InstallationIndoor
CoolingAir cooled
Insulation ClassClass F (or customized)
StandardIEC 60076-6 / AS/NZS aligned
ConstructionAir core, VPI epoxy impregnated
ConductorElectrolytic copper
Starting Current3–3.5× FLC (typical); 1–1.5× FLC with Dynamic Compensator
Reactor Variation5-tap (≈5% voltage difference per tap)

MV integration options

  • Bypass vacuum contactor or bypass VCB
  • Line-side soft starter options for hazardous areas
  • Fault level considerations included in design
  • PLC closed-loop control for performance

Design assurance

  • Impedance measurement to validate starting current
  • Tap flexibility to accommodate motor tolerances
  • Thermal & electrical margin for extended lifetime

Product features

Built for Long Life, Accuracy & Reliability

Key engineering and manufacturing practices that help ensure stable starts and dependable performance.

VPI Resin Impregnation

Vacuum Pressure Impregnation with epoxy resin improves mechanical strength and insulation integrity.

Thermal & Electrical Margin

High design margins considered in electrical and thermal design to support extended service life.

Inductance Tolerance Control

Designed with inductance tolerance and aligned with IEC/AS-NZS 60076-6 requirements.

Maintenance-Free Reactor

Environment-friendly and rugged construction—reduces routine maintenance workload.

Impedance Measurement

Reactor impedance measurement supports predictable starting current and site outcomes.

Power-System Engineering Support

Support with voltage drop, starting kVA impact, and practical integration into your network.

How we deliver

Soft Starter Project Workflow

A structured approach—from engineering inputs through commissioning—so your motor starting performance is predictable, compliant, and reliable.

  1. 1

    Data Collection & Starting Constraints

    Motor data, load type, inertia, duty cycle, weak-grid/generator constraints, allowable voltage drop, starting time, and site standards.

  2. 2

    Engineering Design & Tap Selection

    Reactor design and tap selection based on torque-speed/current-speed curves; confirm starting current target and performance commitments.

  3. 3

    Panel, Bypass & Controls Integration

    Bypass contactor/ACB (LV) or vacuum contactor/VCB (MV), PLC closed-loop controls, interlocks, protection, and HMI.

  4. 4

    Factory Tests & Commissioning

    Impedance checks, functional tests, documentation, commissioning support, and site tuning to confirm voltage dip and starting current outcomes.

Where it fits

Industries & Applications

Reactor-based soft starters are widely adopted where high reliability, reduced voltage dip, and motor protection are critical.

Water Treatment & Water Supply

Pumping stations, high-inertia starts, voltage dip constraints.

Steel Plants

Fans, blowers, mills and heavy process drives.

Infrastructure & HVAC

Large fans, blowers and chillers needing stable starts.

Pharma & Process

Reliability and clean power in controlled environments.

Oil & Gas

Compressors and captive power plants with strict starting limits.

Fertilizers

Large motors on constrained networks and industrial utilities.

Automotive

Robust starting for process ventilation and pumping loads.

Textiles & Paper Mills

Fans/blowers and process drives with repetitive starting duty.

Case studies

Proven Starting Performance On Site

Example applications where reduced starting current and voltage drop performance were achieved.

Coal Mine Shovel

  • Motor: 560 kW, 6.6 kV
  • Outcome: Starting current limited to ~1.5× FLC
  • Note: Panel customized for vehicle space constraints

Iron & Steel Plant

  • Motor: 3.2 MW, 11 kV
  • Challenge: Transformer overload risk with DOL
  • Outcome: Controlled start without transformer overloading

Oil Exploration Captive Plant

  • Motors: 1350 kW & 1885 kW @ 6.6 kV (compressors)
  • Outcome: <2.5× FLC start, <2% voltage drop
  • Supply: 2× generators in parallel

Irrigation Pump (11 kV)

  • Motor: 10.5 MW, synchronous
  • Outcome: Reduced starting kVA and controlled voltage drop
  • Result: Stable acceleration time under site constraints
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About us

About iEngineering – where vision meets execution!

iEngineering delivers industrial electrical and energy solutions across Australia, Fiji, and India—covering power quality, switchboards, transformers, LV/MV panels, EV charging, solar & BESS, and engineered motor starting systems. Our soft starter solutions are supported by power-system engineering, practical integration, and reliable local support.

Our Mission

To enhance efficiency, ensure quality, and deliver customer satisfaction through innovative engineering solutions. We are committed to global standards and sustainable outcomes that create long-term value.

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Our Vision

To be a trusted engineering partner across Australia, Fiji, India and the Pacific—delivering intelligent, resilient and low-carbon infrastructure for utilities and industry.

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Our Values

Integrity, safety and accountability—backed by practical innovation, clear communication, and long-term partnerships.

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Our Journey

Founded in 2013, iEngineering delivers high-quality electrical and energy hardware solutions tailored for Australian and Pacific conditions—backed by design, engineering, testing, and commissioning support.

Where We Operate

iEngineering operates across Australia, Fiji, and India—supporting organisations from local enterprises to multinational operators with reliable technology and engineering services.

India – Pune

Phone: +91 9168627258

Email: shila@iengaust.com.au

Navale IT Zone, Office No. 501, 5th Floor, A-Wing, Near Navale Bridge, Mumbai-Bangalore Highway, Narhe, Pune – 411041.

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FAQ

Reactor-Based Soft Starters – Common Questions