Home

Altistart® 48 Y-Range Soft Start Controllers

1. w Shunt Trip See 1 1 A gt 1 co ELE AC LINE Y 3 L2 SUPPLY BY co I 2 2 PM A l 5 L3 e Komm TI r3 FUA d TOCONTROL lt GND O CH I 1 POWER l S l TRANSFORMER e I I Bectapeeeee d FU Fus 11 EO 7 B ux TE Lt J I ATS48 SC un LI A l Eer SEE EE DETAILB 120V Fur E FUA cL2 MOTOR FAULT THERMAL SW RIA RIC ZC oi SCHEER f p re S TS FR Z i TRIP k Ca kd RELAY TS TR LAN CB SHUNT E Ge TRIP COIL I 2 SEC P i r 4G L RUN KEE DO Joss l l py WU UN l I 1 PESE l SEE i poo 2 RUN COMMAND 0 DETALA og ROR e n i ae I dl Eu L wg 14 1 I Ges 1 i cce o E Lat ae Eur i er i e bas i n END i quA m QE SHORTING END P d Lo H SCA e CONTACTOR START UP 1 LJ 1 1 PILOT RELAY I m ro od i Kee l 37s rF i SCA Fw d SHORTING PROGRAMMABLE BEEN QNNM i ei Ze N O CONTACT t hd r Sc r e CONTACTOR l O l a l i slk pen 8 ij yore O Connect control power transformer l ENEE 4 R L ____ POWER ON for 120 V secondary voltage J ia 2 For shorting contactor operation add SC with associated control circuit DETAIL A 120 V RCR CONTROL 3 Relay contact located on ATS48 uirga a C EC GL ae re gigs ee EC M CM MM oe controller 2 WIRE CONTROL W AUTO AVRE CONTROR
2. Altistart 48 Y Range Soft Start Controllers S1A37491 Section 5 Wiring 01 2010 Figure 15 Power Connections ATS48C79Y to M12Y 5 13 8 13 8 101 9390 350 18x014 mm H d 1 0 6 1 0 26 Y 2 4 2 M10 BZ Ke 80 4 0 az 99 BIER 3 80 g0 1 0 Dims in 74 204 10 229 26 mm 7 18 726 Control Connections Although all control inputs and outputs of the controller are isolated from the input lines follow these control wiring precautions 34 Keep control wiring conductor runs short and direct Ensure that the control contacts used with the controller inputs are rated for operation at open circuit voltages of 24 Vdc and closed circuit currents of 10 mAdc The analog output requires twisted cable with a pitch of 1 2 inches Use a cable shield The shield must be terminated to ground at one end Ensure that the coils of all relays and solenoids connected to the output contacts of the controller are equipped with appropriate transient suppressors For proper control wiring route conductors to avoid contact with other voltage potentials in the controller Wire insulation must have the appropriate voltage rating for the voltage present The control terminals are fitted with one way plug in connectors with Maximum wire size 12 AWG 2 5 mm Maximum tightening torque 3 5 Ib in 4 Nem On ATS48C17Y to ATS48M12Y the cover must be removed
3. i 0 8 9 M6 ggg 20 04 ES a 9x99 mm 10 d Y AO r dar 11 3 L2 5 L3 0 04 o o Oo of 1 AAA O O o T o 0 6 fi 1 14 oam o a2 erms y i Y AP p Ph i A2 TN Me 2 C2 1 6 0 04 1 15 24 24 38 62 62 31 Altistart 48 Y Range Soft Start Controllers Section 5 Wiring Figure 13 Dims in mm 32 Power Connections ATS48C21Y to C32Y 0 2 5 4 75 TI 136 5 IM i 0 2 mj 5 5 4 02 1365 SJ 196 5 motor S 1A37491 01 2010 0 8 9x012 mm 20 0 6 T 15 i Y Oo i 1 L1 3 L2 5 L3 0 08 o o o SCH B88 0000 ee o o oj 0 7 18 L3 L3 E 2 71 a 4T2 Ale Y Y 2 A c2 0 08 2 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 5 Wiring Figure 14 Power Connections ATS48C41Y to C66Y 9x14 mm Dims in mm 50 11 2002 2010 Schneider Electric All Rights Reserved 33
4. Table 16 Hot Start Trip Time Severe Application Class 20 Thermal Overload Protection Standard Application Class 10 Thermal Overload Protection 3 In 5 In 3 5 In 5 IN 23s 7 58 32s 15s PTC thermistor probes integrated in the motor to measure the motor temperature can be connected to the control card terminals This analog value is managed by the controller The PTC probe thermal overshoot value can be processed and used in two ways e To stop the machine in the event of a detected thermal trip condition if the signal is active To activate an alarm if the signal is active This alarm can be displayed in a controller status word serial link or on a configurable logic output NOTE PTC probe protection does not deactivate the motor thermal protection provided by the calculation Both types of protection can operate in parallel 41 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 6 Application and Motor Protection 01 2010 Preventive Maintenance The following steps should be done at regular intervals 1 Check the condition and tightness of the connections 2 Make sure ventilation is effective and the temperature around the controller remains at an acceptable level 3 Remove any dust and debris from the controller if necessary 42 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010
5. 6kV person through air 8kV IEC 61000 4 3 Level 3 Radiated electromagnetic fields Equipment transmitting radio 10 V m frequencies Immunity tests IEC 61000 4 5 Level 4 Rapid electrical transients e Power supply cables A KN Opening closing of a contactor e Control supply cables 2kV IEC 61000 4 5 Level 3 Shock wave e Phase to Phase 1kV E e Phase to Ground 2kV IEC 61000 4 12 Level 3 Damped oscillating waves 1kV 1MHz Oscillating circuit on the line supply IEC 60947 4 2 Class A IEC 60947 4 2 Class B on soft starters up to 170 A ATS48D17Y to C17Y shorting bypass contactors must be used Radiated and conducted emissions Fuse selections in Table 8 are based upon 15096 of nominal motor current Ferraz Shawmut fuses are recommended for the overcurrent protective device OCPD Table 8 Short Circuit Protection Device Type 1 Coordination Short Circuit Current Recommended OCPD Rating A 9 Catalog Number Fuse Class Rating 575 V Time Delay A 208 V 230 V 460 V 575 V ATS48D17Y J 5000 15 20 20 25 ATS48D22Y J 5 000 25 30 30 30 ATS48D32Y J 5 000 35 40 40 40 ATS48D38Y J 5 000 45 50 45 ATS48D47Y J 5 000 60 60 60 ATS48D62Y J 5 000 70 80 80 80 ATS48D75Y J 10 000 90 100 100 90 ATS48D88Y J 10 000 110 125 110 110 ATS48C11Y J 10 000 125 150 150 150 ATS48C14Y J 10 000 175 200 175 175 ATS48C17Y J 10 000 200 225 225 225 ATS48C21Y J 10 000 250 300 250 300 ATS48C25Y
6. Functions INTELE braking stop Force freewheel stop Thermal protection Loss of a motor phase Test on small motor Preheating 3 Soft stop INTELE braking stop Force freewheel stop Thermal protection Loss of a motor phase Test on small motor Cascade Preheating 3 Compatible functions Not significant 1 Motor phase loss not detected 2 While the motor is preheating the thermal protection is disabled Set the preheating current IPr 3 In order for this feature to take effect press ENT for 10 s confirmed by flashing display This parameter cannot be modified via the remote keypad display 67 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 7 Programming 01 2010 68 2002 2010 Schneider Electric All Rights Reserved 1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Section 8 Detected Fault and Operating Condition Management Section 8 Detected Fault and Operating Condition Management Soft Starter Does Not Start No Error Code Displayed Conditions Requiring a Power As a general rule if a problem arises when the soft starter is started it is advisable to restore the factory settings and reprogram your settings one by one If this does not fix the problem follow the instructions below Determine whether or not the status code displayed corresponds to the normal state of the soft starter
7. Braking 38 S1A37491 01 2010 Figure 17 Torque as a Function of Applied Voltage Torque Va 2 Ta T Lal di d V Tg Torque developed at full voltage Tg 7 Torque developed with reduced voltage 47 d lad VM Nominal voltage V Reduced voltage 0 Rated 0 025 05 0 75 1 Speed Figure 18 Torque as a Function of Starting Current Current ly Io l load lq Starting current at full voltage locked rotor amps Tat KEE e le Current limit during Soft Start 0 Rated 0 025 05 075 1 Speed A soft start progressively increases voltage to the motor By ramping the voltage the ATS48 soft starter limits the amount of current the motor can draw during starting to a user defined setting Figure 18 shows the speed torque characteristics of a motor as a function of starting current The ATS48 soft starter provides optimal acceleration by ramping the acceleration torque within the envelope of curve Tq When using INTELE braking the stop time t3 is less than the freewheel stopping time t1 INTELE braking is a two part braking process which does not require external components It produces less motor heat than traditional DC injection braking INTELE braking is best used when all of the criteria below are met e 4 pole or 6 pole motors only motor slip is less than or equal to 3 2 t sec ee where t sec Calculated value must be equal to or less than 40 WK Connected motor load inertia Ib
8. Description Setting Range Factory Setting Stator loss compensation 0 to 90 50 Parameter active in acceleration phases and deceleration phases if StY is set to d L 5E Inthe event of torque oscillations reduce this parameter gradually until the device is functioning correctly Oscillations are most common if the soft starter is connected in motors with excessive slip Deceleration gain for torque control 10 to 50 40 This parameter can only be accessed if CLP is set to On and if the StY parameter SEt E 1G Settings menu is set to d It can be used to eliminate instability during deceleration Adjust the parameter in accordance with the oscillations Activation of the cascade function On OFF OFF e OFF function inactive e On function active Cer This parameter can only be accessed if relay R1 has previously been assigned to the isolation relay function and if the forced freewheel stop and motor preheating functions are not configured in parameters LI3 or LI4 IO menu Assign an input LI LIC 255 motors max Line voltage 180 to 790 V 460 V UL This parameter is used to calculate the power displayed LPr and LAP parameters from the SUP menu The display will only be accurate if this parameter has been set correctly Line frequency 50 60 AUt AUt e 50 50 Hz monitoring tolerance of frequency error code FrF 20 e 60 60 Hz monitoring toleranc
9. When changing the factory configuration record your parameter settings in the Factory Settings table beginning on page 75 When first commissioning an ATS48 controller on a 60 Hz system perform a factory parameter reset see FCS on page 56 Programming the ATS48 controller is simplified by internal sequence selections and interlocks For ease of setup access the menus in the following order 1 lO Assignment of the inputs outputs 2 drC Advanced settings 3 SEt Settings Some steps may not be necessary Copy and use the Factory Settings table on pages 75 78 to record your settings 2002 2010 Schneider Electric All Rights Reserved 43 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 7 Programming 01 2010 Display Unit and Programming Figure 22 Display Functions m7 D sauace 3 seven segment displays Returns to the previous Enters a dE oo menu or parameter or or Wies E en aye increases the displayed parameter or valle value Goes to the next menu or parameter Exits a menu or parameter or aborts the displayed or decreases the displayed value value to return to the previous value in the memory NOTE Pressing A or e does not store the choices To store the displayed choice press En The display flashes when a value is stored Display Principle The display principle for numbers differs depending on the maximum scale of the parameter and its value see Table 17 for examples Ta
10. soft start size The ambient temperature indicated in the table represents the temperature of the air surrounding the ATS48 soft start Any additional temperature factors associated with the enclosure system or actual installation ambient temperature must be considered when determining the actual rated current Ic of the soft start For operating ambient above 40 C 104 F without a shorting bypass contactor and 50 C 122 F with a shorting bypass contactor but not exceeding 60 C 140 F the rated current Ic of the soft start must be de rated by 2 per C 2002 2010 Schneider Electric All Rights Reserved 83 Altistart 48 Y Range Soft Start Controllers S1A37491 Appendix B Recommended Component Lists 01 2010 Table 32 Additional Suggested Components for Standard Duty Applications Ic12 345 1223 45 sc 345 Fusible Disconnect Thermal ATS48 Magnetic Controller Isolation Reversing Mechanical Shorting Power Fuses oa Molded Case Circuit Model Contactor Contactor interlock Contactor Class Rating Fuse Block Switch 1 Breaker AC1 AC1 AC1 6 7 10 D17Y LC1D09 LC1D09 W LC1D09 J 25 60308J HGL36000S15 HDL36030 D22Y LC1D18 LC1D18 n LC1D18 J 30 60308J HGL36000S15 HDL36040 D32Y LC1D25 LC1D25 W LC1D25 J 40 60608J HGL36000S15 HDL36050 D38Y LC1D32 LC1D32 i LC1D32 J 50 60608J HGL36000S15 HDL36060 D47Y LC1D40A LC1D40A LC1D40A J 60 60608J HGL36000S15 HDL36080 D62Y LC
11. Automatic sensing preset 3526 e 60 Hz 56 6 to 63 8 Hz e 50 Hz 47 6 to 52 6 Hz Frequency Manual selection 32096 e 50Hz 40to 60 Hz e 60 Hz 48 to 72 Hz Rated current lc 21 device ratings 17 to 1200 A Silicon control rectifiers SCRs 1800 V peak inverse voltage PIV rating Motor power 3 to 1200 hp Motor voltage 208 230 380 460 575 690 Vac Soft starter control circuit supply 110 Vac 15 to 230 15 Vac 50 60 Hz voltage i i A e ATS48D17Y to C17Y 30 W Maximum control circuit e ATS48C21Y to C32Y 50 W consumption with fans operating atsagcaty to M12Y 80 W e Integrated thermal I t protection for motor Class 2 10 10A 15 20 25 30 or no protection and or thermal protection with positive temperature coefficient PTC probes Motor underload settings Current overload settings Phase reversal Phase loss Automatic restart Protection 2002 2010 Schneider Electric All Rights Reserved 15 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 3 Technical Data 01 2010 The ATS48 controllers conform to IEC 60947 4 2 EMC In steady state they emit a level of interference below the allowable levels defined in the standard Table 7 Electromagnetic Compatibility EMC Examples Standards Test Levels sources of interference IEC 61000 4 2 Level 3 Electrostatic discharge Contact with an electrically charged through contact
12. Many option kits are available for the ATS48 controllers Refer to Appendix C beginning on page 85 Some of the terms and acronyms used in this manual are defined in Table 2 Table 2 Definition of Terms Term Definition FLA Full load amperes the current rating of an induction motor at rated speed and load This value may be found on the motor nameplate Nominal current rating of the ATS48 controller This value may be found on the CL controller nameplate In User defined motor current rating Same as FLA OCPD Overcurrent protective device Tn Nominal motor torque as calculated by the ATS48 controller Vn Nominal voltage of supply power mains supply This should correspond to the motor rated voltage on the motor nameplate Before installing the ATS48 controller read this manual and follow all precautions Before removing the ATS48 controller from its packing material verify that the packing carton is not damaged from shipping Damage to the packing carton usually indicates improper handling If any damage is found notify the carrier and your Schneider Electric representative After removing the ATS48 controller from its packaging inspect it for damage If any shipping damage is found notify the carrier and your sales representative Verify that the ATS48 controller nameplate and label conform to the packing slip and corresponding purchase order 11 Altistart 48 Y Range Soft Start Controllers
13. PHONE FAX SOFT START CONFIGURATION PART NUMBER AT S48 SERIAL NUMBER 6W APPLICATION EQUIPMENT DESIGNATION MOTOR NAMEPLATE DATA HORSEPOWER VOLTAGE 3 PHASE FREQUENCY POLES FLA SERVICE FACTOR MOTOR TYPE DESIGN NEMAA NEMAB _ NEMA C _ NEMAD MOTOR CABLE TYPE APPROXIMATE CABLE LENGTH IN FEET POWER SOURCE AND ENVIRONMENT VOLTAGE BETWEEN L1 ANDL2 _____ VOLTAGE BETWEEN L2 ANDL3 3 VOLTAGEBETWEENL3 ANDL1 SERVICE TRANSFORMER RATING KVA Z FREQUENCY 60uz OR L 50 Hz AMBIENT TEMPERATURES MIN C F MAX C F HUMIDITY ALTITUDE IF GREATER THAN 3300 FEET ABOVE SEALEVEL SPECIFY FT SOFT START ERROR CODES REFER TO TABLES 28 THROUGH 33 FOR POSSIBLE CAUSES amp CORRECTIVE ACTION NON RESET FAULTS AUTO RESET FAULTS MANUAL RESET FAULTS L OLF MOTOR THERMAL CUSTOMER CONFIGURABLE FAULT LI InF ANALYSIS NEEDED L PHF Loss OF PHASE LI SLF SERIAL LINK L OHF sTARTER OR LOSS OF MOTOR PHASE INTERRUPTION THERMAL FAULT LI OCF OVERCURRENT LI Fr F LINE FREQUENCY LI Et F EXTERNAL FAULT L Ot F MOTOR THERMAL OUT OF TOLERANCE FAULT VIA PTC PROBES LI PIF PHASE INVERSION LI USF POWER SUPPLY LI StF EXCESSIVE LI ULF motor STARTING TIME UNDERLOAD LI EEF INTERNAL MEMORY CLF CONTROL LINE LI OLC CURRENT LI Lr F LOCKED ROTOR FAILURE CL1 CL2 OVERLOAD IN STEADY STATE CONTROLLER RESET WHEN L CFF INVALID L CFI IN
14. User supplied 81 Altistart 48 Y Range Soft Start Controllers S1A37491 Appendix A Recommended Wiring Diagrams 01 2010 Figure 35 Reversing with Isolation Contactors A _ nouns Sg c _ Sw ENYN 120V To contro f POWER FUt _ _ _ Ae TRANSFORMER ee 3 MOTOR l E THERMAL SW 8 RRR RUN FWD ATS48 o oe i A 1 RELAY SOFT START Pm Connect control l S AN RFR TS power transformer l 1 for 120 V D RFR i RUN REV secondary voltage i alle RELAY 2 For shorting E contactor I TS operation add SC uL EXE ERC RRR e with associated mal RIO Jee FAULT T circuitry CO d k FR k LZ RELAY RFR IC2 Relay contact located on ATS48 TS controller e RFR Ic2 f UN FORWARD Located at motor I o ey CONTACTOR Jumper if switch not present Set RFR time 1 RRR Ici f LUN REVERSING slightly longer than o Le contactor the expected l kA i deceleration time 1 from rated forward j END TS I speed to zero 1 START UP SHOHTIG speed I R2A R2C 1 i dece eedem eee sesso oI Lio CONTACTOR s Set RRR time i PILOT RELAY slightly longer than i the expected 1 dec
15. d and if the CLP parameter in the drive menu drC is still set to the factory setting On It sets the final torque level from 0 and 100 of the torque estimated at the beginning of deceleration In pump applications deceleration control is not necessarily below a load level set by Ed2 If the estimated torque at the start of deceleration is below 20 i e 20 of the nominal torque controlled deceleration does not activate and the motor changes to freewheel mode Estimated torque as a percentage of the nominal torque Ede 100 804 60 40 End of controlled deceleration Ed2 20 E e SCH Time s 0 L dE2 Maximum torque limit 10 to 200 or OFF OFF This limits the torque reference to avoid regenerative behavior in applications with high EL inertia It can be used for constant torque starting if tq2 tLl e OFF no limit e 10 to 200 limit set as a percentage of the nominal torque Deceleration gain for torque control 10 to 50 40 This parameter can only be accessed if CLP is set to On and if the StY parameter SEt E 128 Settings menu is set to d 62 It is used to eliminate instability during deceleration Adjust the parameter in accordance with the oscillations 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 7 Programming Figure 30 Communication Menu COP Soft starter address Communication speed Communication format FE S
16. drive menu drC is still set to On the factory setting Selects the final torque level 0 and 100 of estimated torque during a type d stop This is the threshold at which the controlled stop ends and the freewheel portion of the stop begins If the estimated torque at the start of deceleration is below 20 i e 20 of the nominal torque controlled deceleration is not activated and the motor changes to freewheel mode Estimated torque as a percentage of the nominal torque 100 804 60 End of controlled deceleration EdC lees e B 0 T T L dEC I 404 20 Time s 48 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Section 7 Programming Table 19 Settings Menu SEt Parameters continued Code Description Setting Range Factory Setting Internal braking torque level 0 to 100 This parameter can only be accessed if StY is set to b Selects the braking torque level for stop type b Braking is active up to 20 6 of the nominal speed The total stop ramp depends on the setting of this parameter and also dependent on the motor loading See EbA below Motor speed 0 96 brC 2 0 bet brC 100 7 0 0 T1 L T2 INTELE djustment of motor braking time stop by EbA Impulse brake injection time T2 T1 x
17. oo ge g Der Motor current II Motor torque ASC Ut u EHA Can be DEH Motor thermal state selected T 1 oco Power factor T I op Active power To access the parameters see Figure 24 on page 45 NOTE Logic input RUN logic input STOP and soft starter shorting bypass contactor control R2 cannot be assigned The I O parameters can only be modified when the motor is stopped 57 Altistart 48 Y Range Soft Start Controllers Section 7 Programming NOTE Shading indicates a typically locked function To unlock the function see LI3 UA Logic inputs In order for functions LIH and LII to take effect ENT must be pressed for 10 s confirmed by flashing display These parameters cannot be modified via the remote keypad display 58 Code S1A37491 01 2010 Table 22 UO Menu IO Parameters Description Setting Range Factory Setting pc LIA ogic inputs SUUM LIL Ls L IH The selected function is active if the input is powered up Speed no not assigned LIA forced freewheel stop It forces the configuration of a freewheel type stop but does not control the stop as soon as a STOP command is received This selection does not appear if the CSC parameter in the drC menu is set to On LIE external fault This enables the soft starter to detect a user defined external fault such as level and pressure The motor comes to a freewheel stop and the soft starter displays EtF LIL force to loc
18. LLUL 0o EUL 4 Alarm Fault Deactivation J ALA JEF OFF EI LE eio CEDE LL Parameters First level parameter settings 77 Second level parameters depend upon choice of first level parameters To access the parameters see Figure 24 on page 45 The protection parameters can only be modified when the motor is stopped 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 7 Programming A DANGER UNINTENDED EQUIPMENT OPERATION The factory configuration of a monitoring alarm ALA indicates the presence of a detected fault but will not directly protect the installation When using automatic restart parameter ArS see Table 20 ensure that an accidental start will not endanger personnel or equipment in any way Failure to follow these instructions will result in death or serious injury Table 20 Motor Protection Menu PrO Parameters Code Description Setting Range Factory Setting Motor thermal protection See Thermal Overload Protection on page 39 e 30 Class 30 e 25 Class 25 EHF e 20 Class 20 severe application e 15 Class 15 e 10 Class 10 standard application e 10A Class 10A e 2 Sub class 2 e OFF no protection Activation of motor underload OFF If the motor torque is less than threshold setting of parameter LUL
19. Section 7 Programming Section 7 Programming Programming and Setup Preliminary Recommendations A WARNING LOSS OF CONTROL COMMUNICATION INTERRUPTION The designer of any control scheme must consider the potential failure modes of control paths and for certain critical control functions provide a means to achieve a safe state during and after a path failure Examples of critical control functions are emergency stop and overtravel stop Separate or redundant control paths must be provided for critical control functions System control paths may include communication links Consideration must be given to the implications of unanticipated transmission delays or failures of the link Each implementation of an ATS48 soft starter must be individually and thoroughly tested for proper operation before being placed into service Failure to follow these instructions can result in death serious injury or equipment damage For additional information refer to NEMA ICS 1 1 latest edition Safety Guidelines for the Application Installation and Maintenance of Solid State Control and to NEMA ICS 7 1 latest edition Safety Standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems If starting the soft starter from line power limit operations to the duty cycle ratings described on page 37 Use inputs LI1 to LI4 to control the soft starter
20. W ONTO FWIRECONIROL l Located at motor Jumper if switch H i OFF Se n f not present i HAND i ebd B STOP START l 8 Use RCR relay logic for 120 V Kyo o o A T o o B control of the ATS48 For 24 Vdc 1 A l l 1 REMOTE OR A See B OR l control omit the RCR relay logic MEME START l and wire controls directly to the E x ATS48 see DETAIL B 1 l l 1 l C 1 I E Cc E a ee EEN Su lied DETAIL B eer supplie a RRS duci A SS i ee Se ee ee 1 120V RCR CONTROL 2 WIRE 24 VDC CONTROL 8 WIRE24 VDC CONTROL i I l STOP D Cr STOP EE gt STOP ales STOP Pd RUN l 1 gt RUN QR gt RUN oR In gt RUN I d RCR OFF ON l i a i a I poeseos gt 424V Lo o gt sev gt av I o 0 I 80 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Appendix A Recommended Wiring Diagrams Figure 34 Nonreversing with Isolation Contactor A _ AC LINE 3 L2 SUPPLY 8 La 5 L3 c l ll I I II TO CONTROL 1 ol l l I POWER Li SC iii Iii TRANSFORMER Fu2 rus I AXE I AE T Vp E J I SC un I Ein Pines ere e PO 120V FU1 FUA Self DCH MOTOR ie i THERMAL SW f SEE ams RUN COMMAND i DETAILA oi RCR
21. and the parameters remain locked XXX parameter access is unlocked the code remains on the screen Toreactivate locking with the same code when the parameters have been unlocked return to On using the W button and then press ENT On appears on the screen to indicate that the parameters have been locked Tolock access with a new code when the parameters have been unlocked enter a new code change the number displayed using the A or Y keys and press ENT On appears on the screen to indicate that the parameters have been locked Toclear locking when the parameters have been unlocked return to OFF using the W button and press ENT OFF remains on the screen The parameters are unlocked and will remain unlocked until the next restart Remember to document your access code password Failure to do so could prevent use of the keypad in programming and configuration modes When access is locked using a code only the monitoring parameters can be accessed and with only a temporary choice of parameter displayed 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Section 7 Programming The choice of application functions can be limited by the incompatibility between certain functions The functions that are not listed in this table are not incompatible with any other functions Figure 32 Compatibility
22. c A ml Ke ge l 1 C bass he 3 TS RCR FAULT RIA R1C LAN FAULT T EJ TT RELAY TS FR RER oA ISOLATION M EJ TT contactor 7s END i START UP Po i ua RO 77 SHORTING A o JL o e SCA e CONTACTOR LJ PLOT RELAY i l i See salis 3 I SCA PES I ri FA x SHORTING SI ae Pe TE ee SC Se CONTACTOR DE 1 Se l I oe OS oe d l yx l 4 WEE POWER ON l ALIA l d P N FR Nov l p Ah l J4 we FAUT 1 PEN l l x a d IC d l 1 TUN e 1L 4G e RUN y L y s DETAIL A fa Mu M DE E EMI D Em me I 2 WIRE CONTROL W AUTO 2 WIRE CONTROL W O AUTO 3 WIRE CONTROL i 1 d OFF OFF ON HAND AUTO e STOP START H o o o A T 6 o B i 1 ww ITT i 1 REMOTE OR A e OR S a d START u 99 e I 1 1 1 I I 2002 2010 Schneider Electric All Rights Reserved ATS48 SOFT START END START UP PROGRAMMABLE N O CONTACT O Connect control power transformer for 120 V secondary voltage 2 For shorting contactor operation add SC with associated control wiring 3 Relay contact located on ATS48 controller Located at motor Jumper if switch not present Set RCR time slightly longer than expected deceleration time from rated speed to zero speed
23. controller e When installing the controller in an enclosure cover the device to prevent metallic debris from falling into the controller The ATS48 controller generates heat and must be properly ventilated Refer to Thermal Considerations for Sizing Enclosures on page 21 to determine power dissipated e When several controllers are installed in a control panel arrange them in a row Do not stack controllers Heat generated from the bottom controller can adversely affect the ambient temperature around the top controller A CAUTION CONTROLLER OVERHEATING HAZARD e Mount the ATS48 controller within X10 of vertical Do not locate the controller near heat radiating elements e Electrical current through the controller will result in heat losses that must be dissipated into the ambient air immediately surrounding the controller To help prevent a thermal fault or equipment damage provide sufficient enclosure cooling and or ventilation to limit the ambient temperature around the controller Failure to follow these instructions can result in injury or equipment damage 2002 2010 Schneider Electric All Rights Reserved 19 Altistart 48 Y Range Soft Start Controllers Section 4 Mounting Mounting in a General Purpose Metal Enclosure Soft Starter Ventilation Mounting in a Dust and Damp Proof Metal Enclosure Figure 8 X Ventilation for Dust and Damp Proof Enclosure i 60 C i 0 i in
24. for longer than the time parameter tUL is set for one of the following occurs e ALA an alarm activates internal bit and configurable logic output e dEF the soft starter will not run and the ULF error code displays e OFF no protection T Cn 100 A ULL lids hysteresis BEEN LUL 20 detection ULL t Motor underload threshold 20 to 100 of Ty 60 LUL This parameter is not available if ULL is set to OFF LUL can be set from 20 to 100 of the nominal motor torque Motor underload time 1to60s 60s LLL This parameter is not available if ULL is set to OFF Time delay tUL activates as soon as the motor torque falls below threshold LUL It resets to zero if the torque rises above this LUL threshold by 10 hysteresis Excessive starting time 10 to 999 s or OFF OFF If the starting time exceeds the value of tLS the soft starter will not run and displays the EL 5 StF error code The conditions for the end of starting are line voltage applied to the motor min firing angle and motor current less than 1 3 ly e OFF no protection 2002 2010 Schneider Electric All Rights Reserved 51 Altistart 48 Y Range Soft Start Controllers Section 7 Programming S 1A37491 01 2010 Table 20 Motor Protection Menu PrO Parameters continued Code Activation of current overload Description Setting Range Factory Setting This function is only active in steady state If the motor current exceeds the th
25. from 0 to 125 9 100 corresponds to the nominal thermal state for the current ly set EHr Motor current LE r in amperes up to 999 A examples 01 5 is 1 5 A 15 0 is 15 A 150 is 150 A A or kA In kiloamperes starting at 1000 A examples 1 50 is 1500 A 1 15 is 1150 A Operating time in hours since the last reset In hours up to 999 hrs examples 001 is 1 hr and 111 is 111 hrs In kilo hours from 1000 to 65535 examples 1 11 is 1110 hrs and 11 1 is 11100 hrs Above 65535 hrs 65 5 the display resets to zero rnb Operating time is counted when the motor is not stopped i e when the h or kh thyristors are fired heating acceleration steady state deceleration braking and in continuous bypass operation The hour counter can be reset in the link mode using the control word or via the keypad display with the motor stopped When the power is removed from the 115 Vac control power supply the hour counter is saved in the EEPROM Active power varies from 0 to 255 Bs 100 corresponds to the power at nominal current and at full voltage Motor torque varies from 0 to 255 SA 100 corresponds to the nominal torque Active power in kW L HP This parameter requires configuration of the exact value of the line voltage kW ULn in the drC menu Display of the current state nLP soft starter without run command and power not supplied rdY soft starter without run command and power supplied tbS star
26. ft Arpm Change in rpm or synchronous speed Te_t Full Load Torque lb ft 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 Motor Protection and Diagnostics Thermal Overload Protection 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Section 6 Application and Motor Protection On all controllers the motor protection features are available even if a shorting bypass contactor is used to bypass the SCRs after the motor is up to speed To assist with troubleshooting the 3 digit LCD displays status codes The controller memory registers and maintains the previous 5 status codes even following power loss The ATS48 controller is a UL Listed motor controller with integrated motor and controller thermal protection The motor and controller temperature are continuously calculated based on the controller nominal current and the current that is actually drawn An electronic circuit which stores the thermal state of the motor even if the supply power is disconnected simulates the cooling curve Overload of any kind over any duration can cause the motor temperature to rise As Figure 19 shows the ATS48 controller creates a digital model of the motor temperature based on two thermal images The first T1 represents the level of temperature rise corresponding to iron motor frame The second T2 represents the temperature rise of copper stator windings For ea
27. guidelines Use metallic conduit for all controller wiring Do not run control and power wiring in the same conduit e Separate metallic conduits carrying power wiring or low level control wiring by at least 3 in 80 mm e Separate non metallic conduits or cable trays used to carry power wiring from metallic conduit carrying low level control wiring by at least 12 in 805 mm e Always cross power and control wiring at right angles Adaptation to Line Input The control circuit is completely independent of the power circuit To apply control voltage follow the instructions on the label located on the controller terminal strip Remove the terminal cover label and connect single phase voltage of 110 to 230 15 Vac supply to terminals CL1 and CL2 The power circuit adapts automatically to the input line voltage and frequency over a range of 208 to 690 V 10 to 1596 for standard controllers 2002 2010 Schneider Electric All Rights Reserved 29 Altistart 48 Y Range Soft Start Controllers Section 5 Wiring Power Connections Table 13 Terminals Power Input Power Output Bypass Shorting Contactor L1 L2 L3 T1 T2 TS8 A2 B2 C2 Wire Size and Tightening Torque Max Wire Size AWG mm ATS48D17Y D47Y 6 AWG 16 mm ATS48D62Y C11Y 2 0 AWG 50 mm ATS48C14Y C17Y Bus Bar 240 mm ATS48C21Y C32Y Bus Bar 240 mm ATS48C41Y C66Y Bus Bar 2x240 mm S 1A37491 01 2010 ATS4
28. in order to access the control terminals 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 Layout of Control Terminals Altistart 48 Y Range Soft Start Controllers Section 5 Wiring Figure 16 Control Terminals o la lo la lo blz 15 S ke N gt e A jg a ja e fe gt Je x o o r amp IS le je e amp je 9 5 amp 9 9 9 2 8 E E RJ 45 Table 14 Control Terminal Blocks Terminal Function Characteristics 90 to 270 Vac 50 60 Hz CL1 CL2 Control power supply i e Switch mode power supply with 25 VA consumption R1A R1C R1 Relay N O programmable contact Minimum switching capacity 10 mA for 6 Vdc R2A R2C R2 Relay N O starting relay contact Maximum switching capacity on inductive load 1 8 A for 230 Vac and 30 Vdc R3A R3C R3 Relay N O programmable contact Maximum voltage 400 Vac STOP Stop controller 4 logic inputs with 4 3 kQ impedance RUN Run controller Voltage V 30 V max Current I 8 mA max State 1 V 211V 155 mA LI3 L14 Programmable inputs State0 V lt 5V 1 lt 2mA SR 24 V 125 isolated and protected against short circuits and overloads maximum current of 24V Logic input power supply 200 mA LO Logic output power supply Connect to 24 V or an external supply source LO1 2 open collector outputs compatible with Level 1 PLC IEC 60065A 68 standard LO2 Programmable lo
29. must be used with large controllers for this reason they are supplied with lifting holes NOTE Do not rest the unit directly on the bus bar connectors A WARNING HANDLING AND LIFTING HAZARD Keep the area below any equipment being lifted clear of all personnel and property Use the lifting method shown in Figure 3 Failure to follow these instructions can result in death or serious injury 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 3 Technical Data Section 3 Technical Data Technical Characteristics Tables 3 and 4 page 14 describe the technical characteristics of the ATS48 controller The information is based on operation at a maximum ambient temperature of 40 C without a shorting bypass contactor and at 50 C with a shorting bypass contactor The ATS48 controller can be used in an ambient temperature of up to 60 C as long as the maximum current rating for Class 10 thermal overload protection is derated by 2 for each degree above 40 C without a shorting bypass contactor or by 2 for each degree above 50 C witha shorting bypass contactor The nominal motor current ly must not exceed the maximum current rating for Class 10 thermal overload protection Table 3 Standard Duty Application 208 to 690 V Supply 10 to 1526 50 or 60 Hz
30. ned hp kva hp kwe npe kw 2 r eea TMA Ic Rating Catalog Number 208 V 230 V 440 V 460 V 500 V 575 V 690 V 3 9 Overload Protection 5 7 5 10 9 15 15 17 17 ATS48D17Y 7 5 11 15 11 20 18 5 22 22 ATS48D22Y 7 5 10 15 20 18 5 25 22 32 32 ATS48D32Y 10 18 5 25 22 30 30 38 38 ATS48D38Y 15 22 30 30 40 37 47 47 ATS48D47Y 15 20 30 40 37 50 45 62 62 ATS48D62Y 20 25 37 50 45 60 55 75 75 ATS48D75Y 25 30 45 60 55 75 75 88 88 ATS48D88Y 30 40 55 75 75 100 90 110 110 ATS48C11Y 40 50 75 100 90 125 110 140 140 ATS48C14Y 50 60 90 125 110 150 160 170 170 ATS48C17Y 60 75 110 150 132 200 200 210 210 ATS48C21Y 75 100 132 200 160 250 250 250 250 ATS48C25Y 100 125 160 250 220 300 315 320 320 ATS48C32Y 125 150 220 300 250 350 400 410 410 ATS48C41Y 150 250 350 315 400 500 480 480 ATS48C48Y SS 200 355 400 400 500 560 590 590 ATS48C59Y 200 250 400 500 600 630 660 660 ATS48C66Y 250 300 500 600 500 800 710 790 790 ATS48C79Y 350 350 630 800 630 1000 900 1000 1000 ATS48M10Y 400 450 710 1000 800 1200 1200 1200 ATS48M12Y 2002 2010 Schneider Electric All Rights Reserved 13 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 3 Technical Data 01 2010 Table 4 Severe Duty Application 208 to 690 V Supply 10 to 15 50 or 60 Hz hp hp Kw O hpg kwa hp We ENA lo Ratin Catalog Number 208V 230v 440V 460V 500V 575V 690v d cL nating g Overl
31. of the nominal torque EaD 0 acc Type of stop d b F F Three types of stop are possible e d Soft stopping by control of motor torque The soft starter applies torque to the SEY motor in order to decelerate progressively on the ramp avoiding a rapid stop This type of stop reduces the risk of water hammer on a pump e b INTELE braking stop The soft starter generates braking torque in the motor which will slow the motor down if there is considerable inertia See page 38 e F Freewheel stop The soft starter applies no torque to the motor 47 Altistart 48 Y Range Soft Start Controllers Section 7 Programming S1A37491 01 2010 Table 19 Settings Menu SEt Parameters continued Description Setting Range Factory Setting Code dEL Edl Deceleration ramp time 1to 60s 15s This parameter can only be accessed if StY is set to d Selects the time 1 to 60 s the soft starter will take to reduce the estimated torque to zero during a type d stop This setting determines the gradient of the torque ramp on deceleration This feature is useful in pumping applications to help prevent hydraulic shock which may occur if the motor decelerates too quickly Estimated torque as a percentage 4 of the nominal torque 100 80 60 40 20 Time s 0 dEC Le Final deceleration torque 0 to 100 20 This parameter can only be accessed if StY is set to d and if the CLP parameter in the
32. or 300 of Iy for 46 seconds from a cold state e Starting at 400 of Iy for 12 seconds or 300 of Iy for 23 seconds with a load factor of 50 and 10 starts per hour or an equivalent thermal cycling e The motor thermal protection conforms to Class 10 overload protection In severe duty applications the ATS48 soft starter is designed to provide e Starting at 400 of Iy for 48 seconds or 300 of Iy for 90 seconds from a cold state e Starting at 400 of Iy for 25 seconds with a load factor of 50 and 5 starts per hour or an equivalent thermal cycling The motor thermal protection conforms to Class 20 thermal overload protection The key to applying a soft start successfully is matching the load to the motor capability while starting with reduced voltage applied The asynchronous motor associated with the ATS48 soft starter must be able to accelerate the driven load when supplied with reduced voltage and current When reduced voltage is applied to a motor during acceleration the current the motor draws is reduced by the ratio of the voltage applied The torque produced by the motor varies with the square of the voltage at a fixed frequency Figure 17 on page 38 shows the speed torque characteristics as a function of the supply voltage Iy is the user defined motor current rating It is the same as full load amperes FLA 37 Altistart 48 Y Range Soft Start Controllers Section 6 Application and Motor Protection INTELE
33. time 10 0 1 to 600 s o5 a LU oa 321 reverse L3 L2 L1 PHr Protection against line phase inversion no 123 forward L1 L2 L3 no no monitoring Eb5 Time before starting 2 0 to 999 s PHL Phase loss threshold 10 5 to 10 Activation of motor monitoring by PTC OFF PEC SE OFF dEF treated as fault H ALA treated as alarm Ars Automatic restart OFF OFF On rEH Reset motor thermal state No No YES 2002 2010 Schneider Electric All Rights Reserved 75 Altistart 48 Y Range Soft Start Controllers Section 8 Detected Fault and Operating Condition Management Factory Settings continued S 1A37491 01 2010 Code Designation Factory Setting Customer Setting Parameter Range and Units EL I Torque limit OFF OFF 10 to 200 of Ty bt Voltage boost level OFF 50 to 100 of mains voltage SSE Tests on a small motor OFF On OFF CLP Torque control type of control On On OFF o o E LSC Stator loss compensation 50 0 to 90 st o So 3 E IL Deceleration gain for torque control 40 10 to 50 e E CSC Activation of cascade function OFF On OFF lt UL na Line voltage 690 180 to 790 V Fre Line frequency AUt 50 60 AUt rPr Reset kWh or the operating time No No APH trE FL5 Return to factory settings No No YES 76 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 Factory Settings continued Code Designation Factory Setting Altistart 48 Y Range Soft Start C
34. 1D50A LC1D50A 11 LC1D50A J 80 61038J HGL36000S15 HDL36090 D75Y LC1D80 LC1D80 11 LC1D80 J 100 61038J HGL36000S15 HDL36100 D88Y LC1D80 LC1D80 11 LC1D80 J 120 62003J JGL36000S25 HGL36110 C11Y LC1D115 LC1D115 B LC1iD115 J 150 62003J JGL36000S25 HGL36150 C14Y LC1D115 LC1D115 n LC1iD115 J 200 62003J JGL36000S25 JGL36200 C17Y LC1F150 LC1F150 LA9FF970 LC1F150 J 225 64033J LHL36000M LAL36225 C21Y LC1F185 LC1F185 LA9FG970 LC1F185 J 300 64033J LHL36000M LAL36250 C25Y LC1F225 LC1F225 LA9FJ970 LCiF225 J 350 64033J LHL36000M LAL36350 C32Y LC1F330 LC1F330 LA9FJ970 LC1F330 JI 400 64033J LHL36000M LAL36400 C41Y LC1F400 LC1F400 LA9FJ970 LCiF400 J 500 6633J PJL36000860 MGL36500 C48Y LC1F500 LC1F500 LA9FJ970 LC1F500 J 600 6633J PJL36000860 MGL36600 C59Y LC1F500 LC1F500 LA9FJ970 LC1F500 L 700 3 PJL36000S80 MGL36800 C66Y LC1F630 LC1F630 LA9FJ970 LCiF630 L 900 3 PJL36000S80 MAL36900 C79Y LC1F630 LC1F630 LA9FL970 LC1F630 L 1100 3 PJL36000810 1 M10Y LC1F780 LC1F780 LA9FL970 LC1F780 L 1350 3 PJL36000810 12 M12Y LC1F780 LC1F780 LA9FX970 LC1F780 L 1600 9 PJL36000812 12 1 2 84 For more UL508A combinations go to www schneider electric us All coils are selected for 120 V 60 Hz operation Refer to the Digest for additional coil voltages or auxiliary contact configurations One block may be added to each contactor Power terminals are not included with LC1 F contactors Refer to the latest editions of Schneider
35. 7491 01 2010 Altistart 48 Y Range Soft Start Controllers Section 2 Receiving and Handling Section 2 Receiving and Handling Introduction Terminology Receiving and Preliminary Inspection 2002 2010 Schneider Electric All Rights Reserved The Altistart 48 ATS48 soft starter offers state of the art acceleration and deceleration control of standard three phase asynchronous induction squirrel cage motors The ATS48 controller uses a patented technology to control the motor performance based on the motor torque rather than simple voltage or current based control Advanced control algorithms are incorporated to help ensure smooth rotation throughout the starting ramp without mechanical instability at the end of starting A microprocessor monitors the motor and controller performance for added protection of the controller motor and driven machinery A variety of starting and stopping modes are standard A digital keypad display is provided for controller setup and motor performance display The ATS48 controller is available in twenty one current ratings from 17 to 1200 A All models use a common control interface for consistent and simple set up ATS48 controllers are rated for use with 208 to 690 V motors and are self adjusting for a 50 or 60 Hz supply frequency This instruction bulletin covers the technical characteristics specifications installation wiring programming and troubleshooting of all ATS48 controllers
36. 8C32Y 50W 902 W ATS48D38Y 25 W 116 W IATS48C41Y 80 W 1339 W ATS48D47Y 25 W 142 W ATS48C48Y 80 W 1386 W ATS48D62Y 25W 201 W ATS48C59Y 80 W 1731 W ATS48D75Y 25 W 245 W IATS48C66Y 80 W 1958 W ATS48D88Y 25 W 290 W IATS48C79Y 80 W 2537 W ATS48C11Y 25W 322W ATSA8M10Y 80W 2865 W ATS48C14Y 25 W 391 W ATS48M12Y 80 W 3497 W ATS48C17Y 25 W 479 W The total dissipated Watts loss is provided strictly for sizing the environmental HVAC cooling requirements based upon nominal current operating conditions The control power circuit consumption is 25 W 2002 2010 Schneider Electric All Rights Reserved 21 Altistart 48 Y Range Soft Start Controllers Section 4 Mounting Remote Keypad Display if used 22 S 1A37491 01 2010 A WARNING LOSS OF CONTROL The designer of any control scheme must consider the potential failure modes of control paths and for certain critical control functions provide a means to achieve a safe state during and after a path failure Examples of critical control functions are emergency stop and overtravel stop Separate or redundant control paths must be provided for critical control functions System control paths may include communication links Consideration must be given to the implications of unanticipated transmission delays or failures of the link Each implementation of an ATS48 soft starter must be individually and thoroughly tested for proper operation before being placed in
37. 8C79Y M12Y Bus Bar 4x240 mm Tightening Torque Ib in Nem 26 Ib in 3 Nem 88 Ib in 10 Nem 300 Ib in 34 Nem 300 Ib in 34 Nem 500 Ib in 57 Nem 500 Ib in 57 Nem Ground Connections GND 1 Max Wire Size AWG mm 8 AWG 10 mm 4 AWG 16 mm Bus Bar 120 mm Bus Bar 120 mm Bus Bar 240 mm Bus Bar 2x240 mm Tightening Torque E Ib in Nem 2 Requires user supplied lug 30 15 Ib in 1 7 Nem 26 Ib in 3 Nem Power terminals are suitable for use with 75 C rated conductors copper only Figure 11 238 Ib in 27 Nem 238 Ib in 27 Nem 238 Ib in 27 Nem Power Connections ATS48D17Y to C11Y SC 238 Ib in 27 Nem 0000000 DOC o A2 B2 C2 2 71 4 12 6 T3 E 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 Figure 12 Power Connections ATS48C14Y to C17Y 0 2 5 I A 9 2 T o02 5 4 6 E 6 4 1165 Dims in 162 mm motor 2002 2010 Schneider Electric All Rights Reserved o N E Altistart 48 Y Range Soft Start Controllers Section 5 Wiring
38. A beginning on page 79 Figure 1 AC Line supply 1 L1 3 L2 5 L3 Power Block Diagram A2 om 2 T1 4 T2 6 T3 Motor I B2 L7 4e i A2 B2 C2 Soft starter I I C bypass oHe 1 Hm 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Section 1 Quick Start Procedure Figure 2 Control Circuit Terminal Configuration Fault relay Soft starter Control supply ATSA48 Y 110 230 Vac 15 2002 2010 Schneider Electric All Rights Reserved Motor R1F bypass relay powered input Programmable logic outputs Inputs for Programmable j PTC probe logic inputs power supply Logic output power supply Programmable analog output Logic ero PTC2 PTC probe 3 x 250 Q NOTE Wire the fault relay in the line contactor power supply sequence in order to open the electrical circuit in the event of a fault or trip condition 4 Set parameter lw in the SEt menu see page 47 to the motor nameplate current 5 Apply power to the control terminals CL1 and CL2 Do not apply power to the power terminals yet and do not give a run command The soft starter displays nLP to indicate that it is not powered up 6 The ATS48 soft starter is factory configured for most standard duty applications See Table 1 on page 10 for the factory preset values I
39. Altistart 48 Y Range Soft Start Controllers Instruction Bulletin S1A37491 01 2010 For use in the United States of America E 1A37491 01 2010 TABLE OF CONTENTS SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Table of Contents Hazard Categories and Special Symbols AAA 5 Product Support 5 uenerat need fune tae mnes 5 QUICK START PROCEDURE heet dere t inta i Eee eh iad et zoo ei drugs 7 HECEIVING AND HANDLINQ iioii eren pa irc ye Al toti Qa dede een ete cedens 11 yg Le Ten BEE ll Terminology Receiving and Preliminary Inspection ss 11 Storing and Shipping eiei pi nena eieaa ea ea EA a EEEa ERES 12 Handling the Controller ecceeceeeeeeseeeeeeeeeeeeeeeseaeeeeeeeeeeseeesseeeseeeseeeeeaees 12 TECHNICAL DATA Ee 13 Technical Characteristics ceeeccececeeseeeeeeeeeeeseeeeeeeeeaeeseaeenaeesieeeeaeeeeeteas 13 Specifications cise et pete rotes teca ERE DR re EE ce pesos 14 Dimensions and Weights AAA 17 Serial and Model Numbers AA 18 MOUNTING o uud BUB eei 19 Mounting Precautions sssseeee mme 19 Mounting in a General Purpose Metal Enclosure 20 Soft Starter Ventilation essen 20 Mounting in a Dust and Damp Proof Metal Enclosure 20 Therm
40. EbA NOTE Time T1 is not determined by brC T1 is the time required in seconds for the motor to fall from 100 of the nominal speed to 20 depends on the motor and application characteristics Injection time at the end of braking 20 to 100 20 This parameter can only be accessed if StY is set to b Selects adjustment of the current injection time at the end of braking for stop type b Can be set at 20 to 100 of the INTELE braking time T1 Example EbA INTELE braking 10 s T1 The stopping time can vary from 2 to 10 s T2 EbA 20 Corresponds to an injection time of 2 s EbA 100 Corresponds to an injection time of 10 s Factory setting 20 49 Altistart 48 Y Range Soft Start Controllers Section 7 Programming Figure 26 50 Motor Protection Menu PrO Motor thermal protection Protection classes 10 20 etc Activation of motor underload Excessive starting time in seconds Activation of current overload Time before restarting Phase loss threshold Automatic restart Reset thermal state Motor underload threshold as a percent of the nominal torque Motor underload time Current overload level as a percent of the nominal current Current overload time Acceptance of phase rotation 123 321 Activation of motor monitoring by PTC probes S 1A37491 01 2010 Ul HP a Alarm Fault Deactivation LLH ALAH JEF H UFF l EI
41. Electric s full line product catalogs for additional ordering information The use of transient suppressors across all contactor coils is recommended Refer to the latest editions of Schneider Electric s full line product catalogs for selection of transient suppressors Recommended contactors are sized for a utilization category AC1 rating and must not make or break motor current Sequencing of these contactors must be as shown on the recommended wiring diagrams in Appendix A See pages 80 to 82 According to the National Electrical Code branch circuit overcurrent protection must be provided for each controller Short circuit protective devices recommended in this table are within NEC requirements for Type 1 coordination For 480 V or lower only Reversing contactors for C11 through M12 controllers must be assembled from components Refer to the latest editions of Schneider Electric s full line product catalogs for power connector link and terminal kits Reversing contactor interlock units used for the C79 through M12 controllers are designed for vertical interlocking of the individual contactors Horizontally interlocked contactors are used for D17 through C59 controllers Fuse holder part number references are for Class J fuses only based on Ferraz Shawmut spring reinforced with box type connectors acceptable for Al Cu wiring Class L fuses require bolt on connections to user supplied power bus work The molded case switches and circuit breakers s
42. J 18 000 300 350 350 350 ATS48C32Y J 18 000 400 450 450 400 ATS48C41Y J 18 000 500 500 600 500 ATS48C48Y H i656 A 9r 18 000 600 650 600 ATS48C59Y L 30 000 700 700 700 ATS48C66Y L 30 000 750 900 800 800 ATS48C79Y L 42 000 1000 1000 1000 1100 ATS48M10Y L 85 000 1350 1200 1400 1400 ATS48M12Y L 85 000 1500 1600 1600 1600 16 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 3 Technical Data Dimensions and Weights Figure 4 ATS48D17Y C66Y Table 9 ATS48D17Y C66Y Dimensions ATSA8eeee a b c e G H Weight in mm in mm in mm in mm in mm in mm in mm Ib kg D17Y D22Y D32Y D38Y 6 30 160 10 83 275 7 48 190 0 26 6 6 3 94 100 10 24 260 0 28 7 10 8 4 9 D47Y D62Y D75Y D88Y C11Y 7 48 190 11 42 290 9 25 235 0 39 10 5 91 150 10 63 270 0 28 7 18 3 8 3 C14Y C17Y 7 87 200 13 39 340 10 43 265 0 39 10 6 30 160 12 60 320 0 28 7 27 3 12 4 E a 12 60 320 14 96 380 10 43 265 0 59 15 9 84 250 13 78 350 0 35 9 40 1 18 2 C41Y C48Y C59Y Ce6Y 15 75 400 26 38 670 11 81 300 0 79 20 11 81 300 24 02 610 0 35 9 113 3 51 4 2002 2010 Schneider Electric All Rights Reserved 17 Altistart 48 Y Range Soft Start Controllers Section 3 Technical Data Figure 5 ATS48C79
43. LII inhibits all protection NOTE Use of this function invalidates the soft starter warranty This is meant to be used to override the soft starter in the event of an emergency smoke extraction system for example Preheating level 0 to 100 096 This parameter appears after LI3 or LI4 have been assigned to function LIH motor preheating It is used to set the preheating current Use a true value current reading ammeter to set the motor current level Parameter Iy has no effect on the IPr current CAUTION RISK OF DAMAGE TO THE MOTOR If the line frequency fluctuates you must use an external device to monitor the frequency and deactivate the preheating function in case of line frequency fluctuations Failure to follow these instructions can result in equipment damage 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 7 Programming Table 22 I O Menu IO Parameters continued Code Description Setting Range Factory Setting Time delay before preheating 0 to 999 mn 5mn Lp This parameter appears after LI3 or LI4 have been assigned to function LIH motor preheating Preheating starts when the input activates after time delays tPr and tbS PrO menu have elapsed tAI Logic outputs ml no not assigned tAl motor thermal alarm see page 39 rnl motor powered AIL motor current alarm threshold OIL a
44. No Error Code Displayed 69 Conditions Requiring a Power Reset A 69 Conditions Requiring a Run Command Reset AA 70 Auto Reset Conditions Customer Configurable A 70 Conditions Requiring Reset by a Repeated 2 times Run Command Input cece A koe Pa re E o ELE Ue EUR A eee 71 Controller Reset Using a Logic Input seeem 72 Troubleshooting Procedure seen een 73 Product Support 2 3 geesde rn o mie ee eed 73 Factory Settings ie tente dece d te ade edge ieee 75 APPENDIX A RECOMMENDED WIRING DIAGRAMS A 79 APPENDIX B RECOMMENDED COMPONENT LISTS sse nennen rennen neret nne trn nnne ennn enne nnns 83 APPENDIX C OPTIONS AND ACCESSORIES AAA 85 INDEX Sushi EBRREBRBBRCE Ienunuaatetmiutarmill ut 87 4 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 Hazard Categories and Special Symbols Product Support 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Table of Contents The following symbols and special messages may appear in this manual or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure A lightning bolt or ANSI man symbol in a Danger or Warning safety label on the equipment indicates an electrical hazard which as indicated below can or will result in personal in
45. Product Support 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Section 8 Detected Fault and Operating Condition Management When troubleshooting the soft starter discuss the symptoms of the reported problem with the operating personnel Ask the operator to describe the problem and to identify when and where it first occurred Then directly observe the controller and process Copy the Troubleshooting Sheet on page 74 and use it to record the controller motor and peripheral equipment nameplate data For support and assistance contact the Product Support Group The Product Support Group is staffed from 8 00 am until 6 00 pm Eastern time Monday through Friday to assist with product selection start up and diagnosis of product or application problems Emergency phone support is available 24 hours a day 365 days a year Toll free 888 SquareD 888 778 2733 E Mail drive products support us schneider electric com Fax 919 217 6508 73 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 8 Detected Fault and Operating Condition Management 01 2010 ALTISTART 48 TROUBLESHOOTING SHEET When requesting after sales service it is important to disclose all conditions under which the Schneider Electric equipment currently operates This will help in diagnosing the system quickly FAX to Product Support 919 217 6508 DATE CONTACT NAME COMPANY ADDRESS CITY STATE
46. Section 2 Receiving and Handling Storing and Shipping Handling the Controller Figure 3 Hoisting the ATS48 Controller 12 1A37491 01 2010 A WARNING DAMAGED SOFT STARTER EQUIPMENT Do not operate or install any soft starter that appears damaged Failure to follow these instructions can result in death serious injury or additional equipment damage If the ATS48 controller is not being immediately installed store it in a clean dry area where the ambient temperature is between 13 and 158 F 25 and 70 C If the ATS48 controller must be shipped to another location use the original shipping material and carton to protect it Do not remove the ATS48 controller from the carton until it is at the final installation site The carton provides protection and helps prevent damage to the controller s exterior Handle the controller carefully after removing it from the carton to avoid damage to the internal components frame or exterior Once removed from the carton the controller can be handled e With a hoist When hoisting the controller attach a spreader bar to the two lifting holes on top of the controller as shown in Figure 3 e Ina horizontal position with the back of the controller resting on a pallet The ATS48 range comprises 6 sizes with various weights and dimensions Small controllers can be removed from their packaging and installed without a handling device A handling device
47. TE Shaded rows indicate typically locked out features S1A37491 01 2010 Refer to Table 18 for soft starter status codes after power up Table 18 Soft Starter Display Status Codes After Power Up Non Programming Conditions Status Code Error code see pages 69 72 Condition Inoperative soft starter Soft starter without run command and nLP Power not supplied rdY Power supplied tbS Starting time delay not elapsed HEA Motor heating in progress Monitoring parameter selected by the user SUP menu Factory setting motor current Soft starter with run command See page 64 brL Soft starter braking Waiting for a command RUN or STOP in Stb cascade mode Figure 25 Settings Menu Nominal motor current In When the current limit is applied to the soft Current limit as a percentage of ly ILE starter the displayed value flashes It is still possible to modify the parameters even if a v A the soft starter detects a fault Acceleration ramp time ACEC Initial starting torque Deceleration INTELE Freewheel 0 pump Braking Type of stop F LL Parameters First level parameter settings i Second level parameters depend upon choice of first level parameters To access the parameters see Figure 24 on page 45 46 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 2002 2010 Schneider Electric All Rights Reserve
48. This allows operation of the soft starter in an enclosure with a maximum internal temperature of 140 F 60 C Ensure that the ambient temperature around the soft starters does not exceed this limit To reduce temperature rise within the enclosure use a shorting bypass contactor duty cycle not to exceed 2 starts per hour or a heat exchanger Derate the soft starter current ly by 2 per C for temperatures above 40 C if a shorting bypass contactor is not used 2002 2010 Schneider Electric All Rights Reserved 1A37491 01 2010 Section 4 Mounting Thermal Considerations for Sizing Enclosures Altistart 48 Y Range Soft Start Controllers manufacturers recommendations for proper sizing based on thermal considerations For this it is necessary to sum the power dissipated by each device in the enclosure Table 12 lists the steady state power dissipation for the ATS48 soft starter operating at rated current with and without a shorting bypass contactor Table 12 Watts Loss Information Power Dissipation in Watts Power Dissipation in Watts When mounting the ATS48 soft starter in an enclosure use the enclosure Catalog Number with Shorting Bypass without Catalog Number with Shorting Bypass Without Contactor Shorting Bypass Contactor Shorting Bypass Contactor Contactor ATS48D17Y 15W 59W ATS48C21Y 50 W 580 W ATS48D22Y 15W 74W ATS48C25Y 50 W 695 W ATS48D32Y 25 W 104 W ATSA
49. VALID FAULT IS CLEARED CONFIGURATION POWER UP CONFIGURATION COMM DETAILED DESCRIPTION OF PROBLEM ATTACH WIRING DIAGRAM SCHEMATICS IF APPLICABLE 74 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 Factory Settings Altistart 48 Y Range Soft Start Controllers Section 8 Detected Fault and Operating Condition Management Code Designation Factory Setting Customer Setting Parameter Range and Units In Current setting Depends upon starter 0 5 to 1 3 lg A rating ILE Current limit 400 150 to 500 of In ACC Acceleration ramp time 15 1to60s 2 gg Initial starting torque 20 0 to 100 of Ty o zz D d deceleration w 0 SEY Type of stop F free wheel b braked F free wheel dEC Deceleration ramp time 15 1to60s EdL Final deceleration torque 20 0 to 100 of estimated torque brt Internal braking torque level 50 0 to 100 EbA Injection time at the end of braking 20 20 to 100 EHP Motor thermal protection 10 OFF 2 10A 10 20 25 or 30 OFF ULL Activation of motor underload OFF dEF treated as fault ALA treated as alarm LUL Motor underload threshold 60 20 to 100 of In EUL Motor underload time 60 1to60s ELS Excessive starting time OFF OFF 10 to 999 s ALA treated as alarm D IL Activation of current overload OFF dEF treated as fault OFF no protection 3c 5 9 LOC Current overload threshold 80 50 to 300 of In 9 EUL Current overload
50. Y M12Y S 1A37491 01 2010 Table 10 ATS48C79Y M12Y Dimensions nae a b c e G H Weight es OY 30 31 770 35 04 890 12 40 315 0 79 20 13 78 350 33 46 850 0 43 11 253 6 115 Serial and Model Numbers 18 The serial and model numbers of the ATS48 controller are on the bar code sticker located on the front right hand side of the device Figure 6 Serial Number and Model Numbers Serial Number Cpoooooooo0 2 CT ATS48D75Y gt ATS48D75Y Model Number 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 4 Mounting Section 4 Mounting Mounting Precautions Follow these precautions when mounting the ATS48 controller e Controllers are open devices and must be installed in suitable enclosures or controlled access areas The environment around the controller must meet Pollution Degree 3 requirements as defined in NEMA ICS1 1 or IEC 60664 1 A DANGER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH ATS48 controllers are open devices and must be mounted in a suitable enclosure Failure to follow these instructions will result in death or serious injury e When the installation surface is not even put a spacer behind the controller mounting pads to eliminate gaps Fastening the controller exterior to an uneven surface may damage the
51. al Considerations for Sizing Enclosures 21 Remote Keypad Display TAUSCO EO PR 22 WIRING j _ uisdisesinet a pe mid te er c b ded ieu Set bd sees 25 Installation Precautions A 25 System Grounding 2 2 ee tacet reiner eee ences 28 General Wiring Practices AAA 29 Adaptation to Line Input sssseeen meme 29 Power Connections ente CPI RU E REED Eed 30 Control Connections Inte De eerie Fare EROR ceterae Dn 34 Layout of Control Terminals A 35 APPLICATION AND MOTOR PROTECTION AAA 37 Soft Starter Applications 37 Standard Duty Applications seen 37 Severe Duty Applications AA 37 Reduced Torq e er tenete tede ee ie el ers 37 INFELE Brakihg 1r inten Acie ad anti 38 Motor Protection and Diagnostics AA 39 Thermal Overload Protection 0 ceeceeseeeeeeeeeeeeeeseeeeeaeeeeeeseaeeeeeeeneeees 39 Motor Thermal Protection with PTC Thermistor Probes VAN 41 Preventive Maintenance A 42 PROGRAMMING Lesen HR b etit Tut ode tiet der veteri see tuts 43 Programming and Setup ssssssseseeeeeeeeeeeenee nenne 43 Preliminary Recommendations AAA 43 Display Unit and Programming eee 44 Display Principle irei tetra dtr EEN 44 MIU mE 45 3 Altistart 48 Y Range Soft Start Controllers S1A37491 Table of Contents 01 2010 SECTION 8 DETECTED FAULT AND OPERATING CONDITION MANAGEMENT AAA 69 Soft Starter Does Not Start
52. al control mode If a serial link is used and this function is set the soft starter changes from link mode control via serial link to local mode control via keypad displays Lit reset after motor thermal fault LIC activation of the cascade function This function disables motor thermal protection and requires that relay R1 be configured as an isolating relay It can be used to start and decelerate several identical motors one after the other with a single soft starter Lir controller reset after faults are cleared LIS activation of second set of motor parameters This function allows start and deceleration of two different motors one after the other or one motor with two different configurations using a single soft starter LIH motor preheating This selection does not appear if the CSC parameter in the drC menu is set to On It is used to prevent the motor from freezing or to prevent temperature deviations which may cause condensation If the input is active once the motor has stopped an adjustable current IPr flows through motor after an adjustable time delay tPr This current heats the motor without causing it to rotate IPr and tbr must be adjusted see below RUN IPr current i When the input activates and the motor has stopped and after time delays tPr and tbS PrO menu have elapsed preheating starts Preheating stops if the input deactivates if a run command is sent or if the STOP input activates
53. ance must be performed by qualified personnel The user is responsible for compliance with all international and national electrical code requirements with respect to grounding of all equipment Many parts of this drive controller including the printed circuit boards operate at the line voltage DO NOT TOUCH Use only electrically insulated tools DO NOT touch unshielded components or terminal strip screw connections with voltage present Before servicing the controller Disconnect all power including external control power that may be present Place a DO NOT TURN ON label on all power disconnects Lock all power disconnects in the open position Install and close all covers before applying power or starting and stopping the drive controller Failure to follow these instructions will result in death or serious injury e Voltage and frequency specifications for the input line must match the controller configuration e A disconnect switch must be installed between the input line and the controller 2002 2010 Schneider Electric All Rights Reserved 25 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 5 Wiring 01 2010 A DANGER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH The solid state switches of the ATS48 controllers power circuit do not provide complete isolation from the AC line Due to leakage currents through the solid state switches hazardous voltages can be
54. arily configures the soft starter tbr and FOr for communication with the remote keypad display e OFF function inactive PCt returns to the OFF state when the control voltage is disconnected On the next power up the tbr and FOr parameters return to their initial configuration OFF Parameter Displayed Menu SUP Power factor Motor thermal state as a percent Motor current Operating time since the last reset Active power as a percent Motor torque as a percent Active power in kW Display of the current state ACC rUn dEC etc Last fault detected Phase rotation direction 1 2 3 or 3 2 1 Keypad display locking code Set Uln in the drC menu LL Parameters 2002 2010 Schneider Electric All Rights Reserved Factory Setting S 1A37491 01 2010 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Section 7 Programming The parameters in the SUP menu below can be modified with the motor stopped or running The factory setting displays the motor current parameter LCr To save the chosen display e Press the ENT key once the choice is temporary it will be cleared at the next power up e Press the ENT key again for 2 seconds the display flashes the choice is permanent and cannot be modified Table 25 Parameter Displayed Menu SUP Parameters Code Parameter Unit C05 Power Factor 0 01 Motor thermal state varies
55. ates A cold state is defined as the stabilized motor thermal state when the motor is off Figure 20 shows the approximate trip times for starting from a cold state Figure 20 Cold Start Curves t s 10000 1000 100 Class 30 Class 25 Class 20 Class 15 Class 10 Class 10A Class 2 0 5 112 15 Viy 2 00 2 50 3 00 3 50 4 00 4 50 5 00 5 50 6 00 6 50 7 00 7 50 8 00 Table 15 Cold Start Trip Time Standard Application Class 10 Severe Application Class 20 Thermal Thermal Overload Protection Overload Protection 3 In 5 In 3 5 In 5 In 46s 15s 63s 29s 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 Motor Thermal Protection with PTC Thermistor Probes 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Section 6 Application and Motor Protection Hot state is defined as the stabilized motor thermal state when the motor has been running at full load capacity Figure 21 shows the approximate trip times for starting from a hot state Figure 21 Hot Start Curves t s 10000 1000 100 Class 30 Class 25 Class 20 Class 15 Class 10 Class 10A
56. ble 17 How to Read Displayed Numbers Example Range Display Value Max scale 9990 05 5 5 5 0 1 to 99 9 55 0 55 55 5 55 5 100 to 999 555 555 1000 to 9990 5 55 5550 Max scale 99900 005 5 1 to 999 055 55 550 550 1000 to 9990 5 55 5550 10000 to 99900 55 5 55500 44 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 7 Programming Menus Menus are accessible in the order shown in Figure 23 Figure 23 Accessing Menus XXX Display of soft starter status see Table 18 on page 46 for codes RESET eed Settings e E Advanced settings BE ECK Assignment of the inputs outputs Siri Communication SUP Selection of the parameter 5 displayed and the locking code 1 Menu St2 is only available if the second set of motor parameters function is configured See the I O menu on page 57 To store the displayed choice press ENT The display flashes when a value is stored Navigate through the menus depending upon the button pressed as shown in Figure 24 Figure 24 Accessing Parameters Parameter Value or assignment Menu Gi E 1 flash save Browsing within the menus E aD Next parameter 2002 2010 Schneider Electric All Rights Reserved 45 Altistart 48 Y Range Soft Start Controllers Section 7 Programming NO
57. ch implementation of an ATS48 soft starter must be individually and thoroughly tested for proper operation before being placed into service Failure to follow these instructions can result in death serious injury or equipment damage For additional information refer to NEMA ICS 1 1 latest edition Safety Guidelines for the Application Installation and Maintenance of Solid State Control and to NEMA ICS 7 1 latest edition Safety Standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems 26 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Section 5 Wiring 2002 2010 Schneider Electric All Rights Reserved A WARNING INADEQUATE OVERCURRENT PROTECTION Anovercurrent protective device must be installed on the line side of the ATS48 controller to achieve published short circuit withstand ratings Do not exceed the maximum overcurrent protective device ratings shown in Table 8 on page 16 Do not connect the controller to a power feeder whose short circuit capacity exceeds the controller short circuit withstand rating shown in Table 8 on page 16 Failure to follow these instructions can result in death or serious injury Power factor correction capacitors should not be connected to a motor controlled by an ATS48 controller If power factor correction is required
58. ch thermal image two levels of alarm are detected An overload pre alarm is signaled by logic output LO1 when the motor has exceeded its nominal temperature rise threshold A pre alarm is signaled when the thermal state exceeds 105 for T1 and or 130 for T2 A thermal fault signal stops the motor when the temperature rise exceeds the critical threshold A thermal fault is signaled by relay R1 when the motor thermal state exceeds 110 for T1 and 140 for T2 Figure 19 Thermal Trip Curves 60 mn 5mn j TH 55 T2 Pre alarm Vy The ATS48 controller is preset to provide Class 10 thermal overload protection for standard duty applications The ATS48 controller can be adjusted to provide Class 2 10A 10 15 20 25 or 30 thermal overload protection as necessary Class 2 protection is available for applications such as submersible pumps where very tight control of motor temperature is required Class 30 protection is available for applications such as high inertia loading where a longer than normal starting time is required to accelerate the load to full speed In addition the internal overload protection may be disabled if motor protection is provided externally 39 Altistart 48 Y Range Soft Start Controllers Section 6 Application and Motor Protection 40 S 1A37491 01 2010 The various thermal overload protection classes are defined to meet the standards of IEC 60947 4 2 for starting from both cold and hot st
59. d Altistart 48 Y Range Soft Start Controllers Index P parameter access 45 PCt 64 PHE 66 PHF 71 PHL 52 PHr 52 PIF 69 PtC 52 R r1 59 r1F 59 ril 59 r3 59 rdY 10 46 reversing contactor 84 rl 59 rnt 65 rPr 56 nH 53 S setting factory 75 shorting contactor 84 shunt trip coil 27 79 SLF 72 soft stopping 47 SSt 55 starter status 46 StF 72 stop freewheel 47 INTELE braking 38 47 soft 47 StY 47 T tAl 59 tbr 63 tbS 52 tHP 51 tHr 65 tl2 62 tlG 56 tL2 62 tLI 55 tLP 64 tLS 51 tOL 52 tPr 59 tqo 47 tq2 61 tUL 51 U ULF 72 ULn 56 USF 71 87 Altistart 48 Y Range Soft Start Controllers S1A37491 Index 01 2010 88 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Instruction Bulletin 1A3749101 Schneider Electric 8001 Knightdale Blvd Knightdale NC 27545 USA 1 888 SquareD 1 888 778 2733 www schneider electric us Altistart is a registered trademark of Schneider Electric Other trademarks used herein are the property of their respective owners Electrical equipment should be installed operated serviced and maintained only by qualified personnel No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material 1A37491 01 2010 Replaces 30072 450 61B 05 2008 2002 2010 Schneider Electric All Rights Reserved
60. d Altistart 48 Y Range Soft Start Controllers Section 7 Programming Table 19 Settings Menu SEt Parameters Code Description Setting Range Factory Setting Nominal motor current 0 4 to 1 3 Io i Adjust the value to the nominal motor current indicated on the motor nameplate Ensure that the current is between 0 4 and 1 3 Io Ic soft starter rating The factory setting corresponds to the usual value of a 460 V standardized motor in accordance with NEC and with Class 10 thermal overload protection 150 to 700 of In Current limit limited to 500 of 400 of Iw Jo The current limit ILt is expressed as a percentage of ly It is limited to 500 of Ic soft starter rating see Tables 3 and 4 on pages 13 and 14 ILE Current limit ILt x Iy Example 1 ly 22 A ILt 300 Current limit 300 x 22 A 66 A Example 2 ATS48C21Y with lo 210 A In 195 A ILt 700 Current limit 700 x 195 1365 limited to 500 x 210 1050 A Acceleration ramp time 1to60s 15s This is the rise time of the soft starter torque between 0 and the nominal torque Ty i e the gradient of the torque ramp on acceleration Reference torque as a percentage of T 100 p g N 80 5 ACE 60 40 20 Time s o s d ACC Initial starting torque 0 to 100 of Ty 20 Initial torque setting during the starting phases varies from 0 to 100
61. e of frequency error code FrF 20 Fr E e AUt automatic recognition of the line frequency by the soft starter with monitoring tolerance of frequency error code FrF 5 Selections 50 and 60 are recommended if the power supply is provided by a generating set given their high tolerance Reset kWh or the operating time no APH trE no e no function inactive o APH kWh reset to zero Te trE operating time reset to zero The reset command must be confirmed with ENT APH and trE take effect immediately The parameter then automatically returns to no Return to factory settings no YES no This is used to reset all parameters to their factory settings e no function inactive FOS 1 e YES function active must be pressed and held down for approx 2 s in order to be accepted The display flashes to confirm The FCS parameter then automatically resets to no when you press ESC This parameter cannot be modified via the remote keypad display This information KWh consumed is only visible with the PowerSuite software workshop or online with Modbus address W4074 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 Figure 28 I O Menu IO Assignment of logic input LI3 Assignment of logic input LI4 Preheating level if preheating is selected Time delay before preheating 0 to 999 s Assignment of logic output LO1 Assignment of logic output LO2 Assignment of relay R1 Assignment of
62. ection 8 Detected Fault and Operating Condition Management Factory Settings continued 1A37491 01 2010 Code Designation Factory Setting Customer Setting Parameter Range and Units Inge Nominal motor current Sc upon stanter 0 5 to 1 3 Io A IL 2 Current limit 400 Ge to 700 of In limited to 500 of CL p o9 ACE Acceleration ramp time 15 1to60s o E S 5 Ege Initial starting torque 20 0 to 100 of Ty zu N CH a dEg Deceleration ramp time 15 1 to 60s 3 Threshold for changing to freewheel stop a Ede Mode at end of deceleration 20 0 to 100 of estimated torque ELe Maximum torque limit OFF 10 to 200 E I Deceleration gain for torque control 40 10 to 50 Add Starter address 0 0 to 31 Ebr Communication speed 19 2 4 8 9 6 19 2 5 2 S 801 8 bits odd 1 stop bit oo ere 8E1 8 bits even 1 stop bit z E For Communication format 8n1 8n1 8 bits no parity 1 stop bit S E 8n2 8 bits no parity 2 stop bit OF O ELP Serial link timeout setting 5 0 1 to 60s Configuration of serial link for PCE communications with remote keypad OFF On OFF display 78 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Appendix A Recommended Wiring Diagrams Appendix A Recommended Wiring Diagrams Figures 33 35 pages 80 82 illustrate circuit diagrams for typical non reversing and reversing applications in 2 wire a
63. ectric Customer Service Representative at 1 888 SQUARED 1 888 778 2733 for availability 2002 2010 Schneider Electric All Rights Reserved 85 Altistart 48 Y Range Soft Start Controllers S1A37491 Appendix C Options and Accessories 01 2010 86 2002 2010 Schneider Electric All Rights Reserved 1A37491 01 2010 INDEX A AC2 61 ACC 47 Add 63 AIL 59 AO 59 APC 59 ArS 53 AS2 59 ASC 59 AUL 59 brC 49 bSt 55 C CFF 70 CFI 70 circuit breaker 84 CLF 71 CLP 55 COd 66 contactor isolation 84 reversing 84 shorting 84 COS 65 CSC 56 D DCF 69 dE2 62 dEC 48 E EbA 49 Ed2 62 EdC 48 EEF 69 EtA 65 EtF 72 F factory settings 75 faults auto reset 71 manual reset 72 non reset 69 resettable 70 FCS 56 FOr 63 FrC 56 freewheel stop 47 FrF 71 fuses 16 84 IL2 61 ILt 47 In 47 In2 61 InF 69 INTELE braking stop 38 47 IPr 58 isolation contactor 28 84 L LAP 65 LCr 65 LFt 65 LI3 58 LI4 58 LIA 58 LIC 58 LIE 58 LIH 58 LII 58 LIL 58 Lir 58 LIS 58 Lit 58 LO1 59 LO2 59 LOC 52 LPr 65 LrF 72 LSC 56 Ltr 65 LUL 51 M menus access to 45 advanced setting drC 54 communication COP 63 UO IO 57 parameter displayed SUP 64 protection PrO 50 second motor parameters St2 60 settings SEt 46 N nLP 10 46 O 0459 OCO 59 OCr 59 OHF 72 OIL 52 OLC 72 OLF 72 OPr 59 OtF 72 OtH 59 Otr 59 2002 2010 Schneider Electric All Rights Reserve
64. elected require the addition of operator mechanisms to allow operation from the exterior of an enclosure Refer to the latest editions of Schneider Electric s full line product catalogs for operator mechanism information When using a shunt trip relay for SCR fault isolation order a disconnect switch with suffix 1021 for addition of shunt trip coil The D Line contactor is available as a reversing configuration For these applications change the IC1 part number prefix from LC1 to LC2 to order the IC1 and IC2 combination complete with mechanical interlocks Devices rated above 660 A have not been coordinated with circuit breakers You must use a Class L fuse for overcurrent protection with ATS48 controller models C79 M10 and M12 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Appendix C Options and Accessories Appendix C Options and Accessories PowerSuite Solutions Table 37 PowerSuite Tables 33 37 show the accessories available for ATS48 soft start controllers Table 33 Documentation VVDED302023 Modbus Protocol User s Manual multilingual Communications Ethernet FIPIO DeviceNet Profibus DP User s DEKO Manual CD ROM version only 30072 451 28 Altistart 48 Soft Starts Maintenance and Repair Guide Table 34 Remote Keypad Display Remote mounting kit for keypad display IP54 e 7 segment remote keypad display e Mount
65. eleration time I SCA from rated reverse i T SHORTING speed to zero zz x cdd CMM CMS CONTACTOR speed 1 1 Remove these 1 contacts to inhibit l direction reversal as pe i ee POWER ON without first 1 depressing STOP 1 push button FR D a eege EAGLE User supplied H 1 i Ici URNA e tc PEU NET RUN FORWARD PROGRAMMABLE WI f N O CONTACT Ic2 pen e M a RUN REVERSE 1a DETAIL A a c lr a ee ee ee l l 2 WIRE CONTROL W AUTO START AUTO DIRECTION 2 WIRE CONTROL W AUTO START MANUAL DIRECTION germ eH PI cro E a EK o mA uS ELE e Rr e a m ME a E E EL ee E Fg OFF OFF WI bog HAND AUTO HAND AUTO FWD REV e N jos ds a Log d l l I I io gt FX oO 1 1A I I 1 F R 1 I I I I I 1 1 l l L y I i l 1 gt Lud I T d I REMOTE START START L l l R F 7 Fa E amu UU uen eue ee iU I e ecu e re I Eds 1 l i l li L le Se Sa Ec RS So 82 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Appendix B Recommended Component Lists Appendix B Recommended Component Lists To select control operators push buttons pilot lamps and selector switches control power transformers and wire management devices control and power terminal strips wire terminations indicated on the recommended wiring diagram configurations refer to the latest editions of Schneider Electric s full line product catalogs Tab
66. elow for the indication of these faults and the restart instructions mode When a condition that requires reset by a repeated 2 times run command input is detected the soft starter locks and the motor switches to freewheel The following are signals that the controller has detected a condition requiring reset by a repeated 2 times run command input e Relay R2 opens e Relay R1 opens The error code flashes on the display as long as the fault is present The last 5 error codes are stored and viewable with the PowerSuite software workshop Perform the following steps before restarting the soft starter e Rectify cause of the fault e n2 wire and 3 wire control initiate a new run command rising edge on the RUN input to reset the controller NOTE A reset will not take place on a run command if LI is assigned to the fault reset Llr function e n2 wire and 3 wire control initiate another new run command rising edge on the RUN input to reset the controller 2002 2010 Schneider Electric All Rights Reserved 71 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 8 Detected Fault and Operating Condition Management 01 2010 Table 29 Correcting Conditions That Require Reset by a Repeated Two Times Run Command Input Error Code A X Probable Cause Corrective Action Displayed SLF Serial link fault Check the RS 485 connection e Check the customer designated fault for this er
67. ent in a phase is greater than blockages or equal to 5 Iy for more than 0 2 s e Check the mechanism for wear mechanical play lubrication and blockages Make sure the soft starter and motor are sized properly for the load and application OHF Starter thermal fault e Ifthe soft starter has a fan check its operation Ensure that the air passages are not obstructed and that the heatsink is clean e Observe the mounting recommendations beginning on page 19 e Allow the soft starter to cool before restarting it e Check the mechanism for wear mechanical play lubrication and blockages SEF Excessive starting time fault Check the value of the tLs setting in the PrO menu page 50 Controller Reset Using a Logic Input 72 Make sure the soft starter and motor are sized properly for the load and application If a logic input LI is configured to reset upon a motor thermal fault LIt see pages 57 and 58 or any other condition requiring a run command reset LIr see pages 57 and 58 then for the motor to restart the following conditions must be met The soft starter must send a pulse on logic input LI e n 2 wire control the run command must be maintained on the RUN input n 3 wire control a new run command rising edge must be initiated on the RUN input See Table 2 on page 9 for wiring the logic inputs 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 Troubleshooting Procedure
68. erial link timeout setting ELF Configuration of the link for PE communication with the remote keypad display or the software workshop LLL Parameters The communication menu parameters can only be modified when the motor is stopped The internal protocol used is Modbus A WARNING LOSS OF COMMUNICATION CAN CAUSE LOSS OF PROTECTION When using serial link timeout setting parameter tLP ensure that the time set will not interfere with the safe operation of the machine Failure to follow these instructions can result in death or serious injury Table 24 Communication Menu COP Parameters Code Description Setting Range Factory Setting Add Soft starter address by the RS 485 serial link Oto 31 0 Ebr Communication speed in kbps 4 8 9 6 19 2 19 2 Communication format 801 8 data bits odd parity 1 stop bit 8E1 8 data bits even parity 1 stop bit E 8ni 8n1 8 data bits no parity 1 stop bit 8n2 8 data bits no parity 2 stop bits FOr 2002 2010 Schneider Electric All Rights Reserved 63 Altistart 48 Y Range Soft Start Controllers Section 7 Programming 64 Table 24 Code ELP Description Serial link timeout setting S1A37491 01 2010 Communication Menu COP Parameters continued Setting Range 0 1 to 60 s 5s PLE Figure 31 Configuration of the serial link for communication with the remote keypad display e On function active Tempor
69. f deceleration Maximum torque limiting Immediately Deceleration gain On the next deceleration L Parameters ENTRE j Parameter availability is dependent on the StY setting in the SET menu This menu is only visible if a logic input is assigned to the function for activating a second set of motor parameters LIS in the I O menu 60 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Section 7 Programming Table 23 Second Motor Parameters Menu GO Parameters Code Description Setting Range Factory Setting Nominal motor current 0 4 to 1 3 lg See note Adjust the value of the nominal motor current indicated on the motor nameplate Ensure that the current is between 0 4 and 1 3 Ic soft starter rating See Tables 3 and in 40n pages 13 and 14 NOTE The factory setting of In2 corresponds with the usual value of a 460 V standardized motor in accordance with NEC and with Class 10 thermal overload protection 150 to 700 of In Current limit limited to 500 of 400 of Iw lc The Current limit IL2 is expressed as a percentage of In2 It is limited to 500 of Ic see Tables 3 and 4 on pages 13 and 14 IL amp Current limit IL2 x In2 Example 1 In2 21 A IL2 300 Current limit 300 x 22 A 66 A Example 2 ATS48C21Y with lo 210 A In2 195 A IL2 700 Current
70. f the factory configuration is not suitable for your application refer to Programming on page 43 for information on changing the parameter settings 7 Apply power to terminals 1 L1 3 L2 and 5 L3 The soft starter will display rdY indicating that it is powered up 8 Connect 24 V to the RUN and STOP control terminals to start the system in 2 wire control A WARNING LOSS OF CONTROL COMMUNICATION INTERRUPTION The designer of any control scheme must consider the potential failure modes of control paths and for certain critical control functions provide a means to achieve a safe state during and after a path failure Examples of critical control functions are emergency stop and overtravel stop Separate or redundant control paths must be provided for critical control functions System control paths may include communication links Consideration must be given to the implications of unanticipated transmission delays or failures of the link Each implementation of an ATS48 soft starter must be individually and thoroughly tested for proper operation before being placed into service Failure to follow these instructions can result in death serious injury or equipment damage For additional information refer to NEMA ICS 1 1 latest edition Safety Guidelines for the Application Installation and Maintenance of Solid State Control and to NEMA ICS 7 1 latest edition Safety Standards for Constructi
71. fault levels use properly coordinated external ground fault protection Possible solutions include Time delay fuses coordinated to 125 of motor FLA A properly coordinated external overload relay Failure to follow these instructions can result in death serious injury or equipment damage If system grounding is not adequate to handle ground fault levels which can exceed 1300 of motor full load amps FLA then this device may not protect the branch circuit conductors In this case external ground fault protection must be properly coordinated Recommended solutions include Time delay fuses coordinated to 125 of motor FLA The fuses listed in Appendix B beginning on page 83 are sized to ensure proper coordination and may be used for applications that do not require start times longer than 50 seconds at 300 current limit or 20 seconds at 500 current limit External overload relay For multi motor applications applications in which motor does not match the controller size or applications that use a full voltage bypass scheme an external overload relay can be coordinated to protect conductors from a high impedance ground fault 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 5 Wiring General Wiring Practices When wiring ATS48 controllers follow the wiring practices required by national and local electrical codes In addition follow these
72. gic outputs Power supply 24 V 12 V min 30 V max Maximum current 200 mA per output with an external source Output can be configured as 0 20 mA or 4 20 mA AO1 Programmable analog output e Accuracy 5 of the maximum value maximum impedance 500 Q COM WO common DV Total resistance of probe circuit 750 Qat 25 C PTC1 PTC2 Input for PTC probes e For example three 250 Q probes in series Connector for RJ 45 e Remote keypad display RS 485 Modbus e PowerSuite Communication bus 2002 2010 Schneider Electric All Rights Reserved 35 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 5 Wiring 01 2010 36 2002 2010 Schneider Electric All Rights Reserved 1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Section 6 Application and Motor Protection Section 6 Application and Motor Protection Soft Starter Applications Standard Duty Applications Severe Duty Applications Reduced Torque 2002 2010 Schneider Electric All Rights Reserved The ATS48 soft starter must be selected for the nominal power of the motor and for the type of application standard or severe duty Standard and severe define the limiting values of the current and the duty cycle characteristics The ATS48 controller is factory preset to start the motor in standard duty applications In standard duty applications the ATS48 soft starter is designed to provide Starting at 400 of In for 23 seconds
73. hould the controller detect a fault auxiliary isolation on the line side of the controller is required Use either a circuit breaker equipped with a shunt trip coil or an electromagnetic contactor Connect the isolation device to the fault relay of the controller so that it opens the 27 Altistart 48 Y Range Soft Start Controllers Section 5 Wiring System Grounding 28 S 1A37491 01 2010 controller power circuit in the event of a controller detected fault The isolation device must be capable of interrupting motor locked rotor current Refer to Appendix A beginning on page 79 for typical circuit diagrams that display the logic controlling the isolation device via the fault relay A CAUTION MOTOR OVERHEATING HAZARD If the solid state switches on the ATS48 controller become inoperable single phase operation of the motor can result Usean isolation device consisting of either a circuit breaker equipped with a shunt trip coil or an electromagnetic contactor to open the line side of the controller The isolation device must be capable of interrupting the motor locked rotor current Connectthe fault relay of the controller to open the isolation device in the event of a controller detected fault Failure to follow these instructions can result in injury or equipment damage A WARNING INADEQUATE SYSTEM GROUNDING BRANCH CIRCUIT CONDUCTOR HAZARD If system grounding is not adequate for ground
74. ing kit containing cover screws and an IP54 seal on the VW3G48101 front panel e 9 8 ft 3 m cable with a 9 way SUB D connector for keypad display and an RJ 45 connector for connecting to an ATS48 controller Table 35 Protective Covers for Power Terminals Set of six protective covers for ATS48C14Y to ATS48C17Y to meet GE international touch safe requirements for power terminals Set of six protective covers for ATS48C21Y ATS48C25Y and LA9F703 ATS48C32Y to meet international touch safe requirements for power terminals Table 36 Control Board VX4G481 Control board NOTE The ATS48 controller has 9 unprotected power terminals PowerSuite solutions are compatible with software version 1 30 build 5 Software for Personal Computers VW3A8104 PowerSuite Test and Commissioning Software on CD for use with Microsoft Windows 95 98 and NT and Windows CE v3 0 for Pocket PCs PDA Cable connection kit for the Personal Computer to an ATS48 controller VW3A8106 two connection cables 9 8 ft 3 m each with two RJ 45 connectors one RJ 45 9 way SUB D adaptor one converter marked RS 232 RS 485 PPC with one 9 way male SUB D connector and one RJ 45 connector Factory repaired ATS48 controllers are available within 24 hours from a factory exchange pool or your ATS48 controller can be factory repaired and returned Contact your local Schneider Electric Distributor or the Schneider El
75. ith the RRR relay This coil is attached to the shunt trip coil on the disconnect and will energize 2 seconds after a controller detected fault by the TR timer contact The time delay is to prevent nuisance tripping of the circuit breaker during controller power up or during line undervoltage conditions TR Trip Relay Used in shunt trip circuit breaker logic only coil energized upon a controller detected fault FR Fault Relay Used with logic diagrams that use an isolation contactor The fault relay is energized during normal operation and deenergizes if the controller detected fault contacts open or if the motor thermal switch if supplied opens FR also provides additional contacts for the controller detected fault output To select control operators push buttons pilot lamps and selector switches control power transformers and wire management devices control and power terminal strips wire terminations indicated on the recommended wiring diagram configurations refer to the latest editions of Schneider Electric s full line product catalogs 2002 2010 Schneider Electric All Rights Reserved 79 Altistart 48 Y Range Soft Start Controllers Appendix A Recommended Wiring Diagrams S 1A37491 01 2010 Figure 33 Circuit Breaker Nonreversing with Shunt Trip Fault Isolation
76. ivated In 3 wire control the motor is restarted after the time delay if a new RUN command is sent rising edge The soft starter displays E b 5 during the time delay PHL Phase loss threshold 5 to 10 10 If the motor current falls below this threshold in one phase for 0 5 s or in all three phases for 0 2 s the soft starter will not run and displays the PHF error code Can be set at between 5 and 10 of the lc soft starter rating Activation of motor monitoring by PTC probes ES OFF The PTC probes on the motor must be connected to the correct analog input This protection is independent of the calculated thermal protection tHP parameter Both types of protection can be used simultaneously e ALA an alarm is activated internal bit and assignable logic output e dEF the soft starter will not run and the OtF error code is displayed e OFF no protection 52 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Section 7 Programming Table 20 Motor Protection Menu PrO Parameters continued Code Description Setting Range Factory Setting Automatic restart If this function is active and the soft starter locks on a detected fault the soft starter automatically restarts if the detected fault is cleared and the other operating conditions permit the re
77. jury if the instructions are not followed The exclamation point symbol in a safety message in a manual indicates potential personal injury hazards Obey all safety messages introduced by this symbol to avoid possible injury or death Symbol Name Lightning Bolt ANSI Man Exclamation Point A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided can result in death or serious injury ACAUTION CAUTION indicates a potentially hazardous situation which if not avoided can result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided can result in property damage For support and assistance contact the Product Support Group The Product Support Group is staffed from 8 00 am until 6 00 pm Eastern time Monday through Friday to assist with product selection start up and diagnosis of product or application problems Emergency phone support is available 24 hours a day 365 days a year Toll free 888 SquareD 888 778 2733 E Mail drive products support us schneider electric com Fax 919 217 6508 Altistart 48 Y Range Soft Start Controllers S1A37491 Table of Contents 01 2010 6 2002 2010 Schneider Electric All Right
78. le 31 Suggested Components for Standard Duty Applications Induction Motor M ATS48 Soft Start FU4 Rated hp Catalog No Device Rated Current ATS Control Cat Ce enu M Time Delay 208 V 230 V 460 V 575V 40 C 104 oF Power Burden W Q115V 3 5 10 15 ATS48D17Y 17 25 0 5A 5 7 5 15 20 ATS48D22Y 22 25 0 5A 7 5 10 20 25 ATS48D32Y 32 30 0 6A 10 25 30 ATS48D38Y 38 30 0 6A 15 30 40 ATS48D47Y 47 30 0 6A 15 20 40 50 ATS48D62Y 62 30 0 6A 20 25 50 60 ATS48D75Y 75 30 0 6A 25 30 60 75 ATS48D88Y 88 30 0 6A 30 40 75 100 ATS48C11Y 110 30 0 6A 40 50 100 125 ATS48C14Y 145 30 0 6A 50 60 125 150 ATS48C17Y 170 30 0 6A 60 75 150 200 ATS48C21Y 210 50 1A 75 100 200 250 ATS48C25Y 250 50 1A 100 125 250 300 ATS48C32Y 320 50 1A 125 150 300 350 ATS48C41Y 410 80 1 5A 150 350 400 ATS48C48Y 480 80 15A 200 400 500 ATS48C59Y 590 80 15A 200 250 500 600 ATS48C66Y 660 80 1 5A 250 300 600 800 ATS48C79Y 790 80 15A 350 350 800 1000 ATS48M10Y 1000 80 15A 400 450 1000 1200 ATS48M12Y 1200 80 15A Motor full load currents through 500 hp 460 575 V 250 hp 230 V and 200 hp 208 V are taken from the National Electric Code NFPA 70 2002 Table 430 150 Above these ratings motor full load currents are calculated based upon 1 2 A hp for 460 V and 2 4 A hp for 230 V Motors listed are for standard duty applications For severe duty applications select the next larger
79. limit 70096 x 195 1365 limited to 500 x 210 1050 A Acceleration ramp time 1to 60s 15s This is the rise time of the soft starter torque between 0 and the nominal torque Ty i e the gradient of the torque ramp on acceleration Reference torque 4 as a percentage of Ty 100 80 REZ 60 40 20 Time s e i AC Initial starting torque 0 to 100 of Ty 20 Initial torque setting during the starting phases varies from 0 to 100 of the nominal torque Cn 4 Eg 2002 2010 Schneider Electric All Rights Reserved Time s 0 AC2 61 Altistart 48 Y Range Soft Start Controllers Section 7 Programming Table 23 Code S 1A37491 01 2010 Second Motor Parameters Menu St2 Parameters continued Description Setting Range Factory Setting Deceleration ramp time This parameter can only be accessed if StY is set to d It sets a time from 1 to 60 s to switch from the estimated torque to zero torque gradient of the torque ramp on deceleration when a d stop is applied This modifies the progression of the deceleration and helps avoid hydraulic shocks in pump applications by modifying the gradient of the torque reference Estimated torque as a percentage of the nominal torque 1004 dEg 80 60 40 20 gt Time s 0 lL dE2 A Final deceleration torque 0 to 100 20 This parameter can only be accessed if StY is set to
80. motor is stopped 54 2002 2010 Schneider Electric All Rights Reserved S1A37491 01 2010 2002 2010 Schneider Electric All Rights Reserved Altistart 48 Y Range Soft Start Controllers Section 7 Programming ACAUTION NO BRAKING With parameter dLt only freewheel type stopping is possible Ensure that freewheel stopping is appropriate for the application Cascading is not possible Preheating is not possible Failure to follow these instructions can result in injury Table 21 Advanced Setting Menu drC Parameters Code Description Setting Range Factory Setting Torque limit 10 to 200 or OFF OFF Use this parameter to limit the torque reference to avoid regenerative behavior in EL I applications with high inertia It can be used for constant torque starting if tqO tLl e OFF no limit e 10to 200 limit set as a percentage of the nominal torque Voltage boost level 50 to 100 or OFF OFF If active this parameter applies a user set voltage when a run command is present for 100 ms Once this time has elapsed the soft starter follows a standard acceleration ramp starting at the initial torque value set tq0 This function can be used to avoid any starting torque phenomenon caused by friction on stopping or by mechanical play e OFF Function inactive e 50 to 100 setting as a percentage of the nominal motor voltage U T 100 4 Ts Un bbb Torque ramp 50 T U
81. n tq0 bees 100 ms t NOTE If the motor nominal current is greater than the ATS48 soft starter nominal current and if the bSt value is set too high the soft starter can nuisance trip as an overcurrent OCF error code Tests on small motor On OFF OFF Use this parameter to check the soft starter in a testing or maintenance environment on a motor whose power is very much lower than the soft starter rating in particular for high power soft starters Get lt automatically deactivates the torque control parameter CLP e OFF function inactive e On function active SSt returns to the OFF state as soon as the control voltage is disconnected On the next power up the PHF error code and the CLP parameter return to their initial configuration Torque control type of control On OFF On e OFF function inactive On function active In the On position starting and deceleration follow the torque ramp In the OFF position starting and deceleration are controlled by voltage variation Voltage control is recommended for applications which use motors in parallel on one soft starter or a motor whose power is very low in relation to the soft starter rating When tests on smaller motor SSt is active CLP is set to OFF 55 Altistart 48 Y Range Soft Start Controllers Section 7 Programming 56 1A37491 01 2010 Table 21 Advanced Setting Menu drC Parameters continued Code
82. nd 3 wire control The recommended circuit diagrams include SCR fault isolation for optimal protection of the motor driven machinery and operating personnel Table 30 Description of Logic for Recommended Wiring Diagrams Item Name Description The isolation contactor logic closes IC1 upon a start command and opens IC1 after the stop is complete The RCR IC1 or RFR and RRR for reversing are timed contacts that must have a time delay greater than the deceleration ramp Isolation Contactor Fwd time or the INTELE braking time When a coast stop is selected the time delay must be set for a time that will allow IC1A complete decay of the motor residual voltage The isolation contactor opens immediately upon a detected fault The pilot relay IC1A is required when the IC1 contactor coil exceeds the relay rating IC2 Used for reversing applications only the IC2 must be mechanically interlocked to IC1 A reversing contactor may be Isolation Contactor Rev used for the combination of IC1 and IC2 In general the operation of IC2 is identical to IC1 The pilot relay IC1A is IC2A required when the IC1 contactor coil exceeds the relay rating The shorting contactor is used to reduce the heat dissipated by the controller when the motor is operating at full C speed and voltage The controller provides proper sequencing of this contactor by the end start up relay When the SCA Shorting Contactor and Pilot Relay start is completed the shorting con
83. nd time tOL of PrO menu exceeded See page 52 e AUL motor underload alarm threshold LUL and time tUL of PrO menu exceeded See page 51 e APC motor PTC probe alarm See PtC on page 52 e AS2 second set of motor parameters activated See LIS on page 58 Relay R1 nF e r1F fault relay In this mode relay R1 activates when the soft starter is powered up minimum CL1 CL2 control Relay R1 deactivates when a fault is detected and the motor switches to freewheel mode See the special case when the automatic restart function is activated and Detected Fault and Operating Condition Management on page 69 ril isolation relay Relay R1 is designed to control the line contactor on the basis of the RUN and STOP commands and to indicate detected faults In this mode relay R1 activates by a RUN command or a preheating command It deactivated at the end of braking or deceleration or when the motor switches to freewheel mode after a STOP command It also deactivates when a fault is detected The motor switches to freewheel mode at this point End of Starting Relay R2 The end of starting relay R2 is activated when the soft starter is powered up no faults are detected and the motor has completed the start up phase It is deactivated in the event LUI Lod rd re of a stop request or a detected fault It has one normally open contact N O It can be used to bypass the ATS48 soft sta
84. o C66Y 55 dBA ATS48C79Y to M12Y 60 dBA Soft starter audible noise level Resistance to electrostatic Conforms to IEC 61000 4 2 Level 3 discharges Immunity to radio electric S Conforms to IEC 61000 4 3 Level 3 interference Immunity to rapid electrical x Conforms to IEC 61000 4 4 Level 4 transients 14 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 3 Technical Data Table 5 Environmental Characteristics continued Storage e 18to 158 F 25 to 70 C Operation Ambient air temperature e 14 to 104 F 10 C to 40 C without derating e Up to 140 F 60 C derate the current by 2 for each C above 40 C e 14 to 122 F 10 C to 50 C with user provided shorting bypass contactor 95 without condensation or dripping water conforming Maximum relative humidity to IEC 60068 2 3 Maximum ambient pollution Conforms to IEC 60664 1 Pollution Degree 3 3300 ft 1000 m without derating Above this derate the Maximum operating altitude nominal current by 2 2 for each additional 330 ft 100 m to a maximum of 6600 ft 2000 m Maximum vertical inclination 10 with respect to the Operating position normal mounting position Table 6 Electrical Characteristics Operating category Conforms to IEC 60947 4 2 AC 53a Three phase supply voltage 208 Vac 15 to 690 Vac 10 50 60 Hz
85. oad Protection 5 5 7 5 7 5 10 11 12 17 ATS48D17Y 7 5 10 9 15 15 17 22 ATS48D22Y 7 5 11 15 11 20 18 5 22 32 ATS48D32Y 7 5 10 15 20 18 5 25 22 32 38 ATS48D38Y 10 18 5 25 22 30 30 38 47 ATS48D47Y 15 22 30 30 40 37 47 62 ATS48D62Y 15 20 30 40 37 50 45 62 75 ATS48D75Y 20 25 37 50 45 60 55 75 88 ATS48D88Y 25 30 45 60 55 75 75 88 110 ATS48C11Y 30 40 55 75 75 100 90 110 140 ATS48C14Y 40 50 75 100 90 125 110 140 170 ATS48C17Y 50 60 90 125 110 150 160 170 210 ATS48C21Y 60 75 110 150 132 200 200 210 250 ATS48C25Y 75 100 132 200 160 250 250 250 320 ATS48C32Y 100 125 160 250 220 300 315 320 410 ATS48C41Y 125 150 220 300 250 350 400 410 480 ATS48C48Y 150 250 350 315 400 500 480 590 ATS48C59Y 200 355 400 400 500 560 590 660 ATS48C66Y 200 250 400 500 600 630 660 790 ATS48C79Y 250 300 500 600 500 800 710 790 1000 ATS48M10Y 350 350 630 800 630 1000 900 1000 1200 ATS48M12Y Specifications S Table 5 Environmental Characteristics e IP20 for ATS48D17Y to C11Y Degree of protection e IPOO for ATS48C14Y to M12Y Conforms to IEC 60068 2 27 15g 11ms Shock resistance Conforms to IEC 60068 2 6 NCF 20706 and BV1 Vibration resistance 15mm peak from 2 to 13 Hz e 1 gn from 13 to 200 Hz Audible noise measurements taken from 3 ft 1 m away The noise levels may change depending on the fan characteristics ATS48D17Y to D47Y 52 dBA ATS48D62Y to C11Y 58 dBA ATS48C14Y to C17Y 50 dBA ATS48C21Y to C32Y 54 dBA ATS48C41Y t
86. on 8 Detected Fault and Operating Condition Management Table 28 Auto Reset Condition Correction Error Code Displayed Probable Cause Loss of a line phase Corrective Action Check the line the connection to the soft starter and any isolating devices located between the line and the soft starter such as contactors fuses and circuit breakers e Check the motor connection and any isolating devices PHF Loss of a motor phase i located between the soft starter and the motor such as If the motor current falls below an adjustable threshold PHL for 0 5 s contactors fuses and circuit breakers single phase or for 0 2 s 3 phase This fault can be configured in Check the motor state the Protection menu PrO parameter PHL Ensure that parameter PHL is compatible with the motor Line frequency is out of tolerance e Check the line FrF The tolerance settings related to this error code can be configured in Ensure that parameter FrC is configured properly for the the Advanced settings menu parameter FrC see page 56 line used generating set for example USF Power supply error on a run command Check the power supply circuit and voltage CLF Control line interruption Loss of CL1 CL2 for more than 200 ms Conditions Requiring Reset by a Repeated 2 times Run Command Input If the automatic restart function is not selected see Conditions Requiring Reset by a Repeated 2 times Run Command Input b
87. on and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems Altistart 48 Y Range Soft Start Controllers Section 1 Quick Start Procedure 10 S 1A37491 01 2010 Table 1 Factory Configuration Nominal motor current ly Preset to correspond to 460 V rated motor current based on NFPA 70 NEC Table 430 150 ratings Current limit ILt 400 of the motor current Iw Acceleration ramp ACC Initial torque on starting tq0 15 seconds 20 of the nominal torque Stop StY Freewheel stop F Motor thermal protection tHP Class 10 thermal overload protection curve rdY soft starter ready when power and control voltage are Display present and the motor is not operating nLP when power is not supplied Logic inputs e Li STOP e LS e RUN e LIS e Forced freewheel stop LIA e Ll4 e Forced local mode LIL Logic outputs e LO1 e LO2 e Motor thermal alarm tA1 e Motor powered rnl Relay outputs e R1 e R2 e R3 e Fault relay r1F e Bypass relay at the end of starting e Motor powered rnl Analog output AO Motor current OCr 0 20 mA Communication parameters When connected via the serial link the soft starter has a logic address Add of 0 Transmission speed tbr 19200 bits per second e Communication format FOr 8 bits no parity 1 stop bit 8n1 2002 2010 Schneider Electric All Rights Reserved 1A3
88. ontrollers Section 8 Detected Fault and Operating Condition Management Customer Setting Parameter Range and Units Logic inputs LIA LIL No not assigned LIA forced free wheel LIE external fault LIH not implemented LIL force to local control mode LII inhibition of faults Lt reset motor thermal fault LIC activate cascade function LIR fault reset LIM second configuration Preheating level 0 0 to 100 EPr Time delay before preheating 5mn 0 to 999 minutes LUI Lae Logic outputs tAl rni No not assigned tAl motor thermal alarm rnl motor powered AIL motor current alarm AUL motor underload alarm APC motor PTC sensor alarm AS2 second configuration active Relay R1 nF HIE fault R1I isolation relay IO Menu Management of Inputs Outputs Relay R3 rl No not assigned tAl motor thermal alarm rnl motor powered AIL motor current alarm AUL motor underload alarm APC motor PTC sensor alarm AS2 second configuration active Ag Analog output OCr No not assigned Ocr motor current Otr motor torque OtH motor thermal state OCO power factor OPr active power Configuration of the analog output AO 020 020 0 to 20 mA 420 4 to 20 mA ASC Scaling of the analog output 200 50 to 500 2002 2010 Schneider Electric All Rights Reserved 77 Altistart 48 Y Range Soft Start Controllers S
89. present on the controller load side power circuit whenever power is applied to the line side of the controller Disconnect all power before servicing the controller or motor Failure to follow these instructions will result in death or serious injury e When using an isolation contactor the contactor must close before or at the same time as the application of the controller run command If line power is not detected at the L1 L2 and L3 terminals of the controller within 500 ms of this run command a Phase Failure fault will occur e External overcurrent protection devices OCPD either fuses or a circuit breaker must be installed on the line side connections of the ATS48 controller The maximum recommended OCPD rating along with the associated controller short circuit withstand rating is listed in Table 8 on page 16 A WARNING LOSS OF CONTROL COMMUNICATION INTERRUPTION The designer of any control scheme must consider the potential failure modes of control paths and for certain critical control functions provide a means to achieve a safe state during and after a path failure Examples of critical control functions are emergency stop and overtravel stop Separate or redundant control paths must be provided for critical control functions System control paths may include communication links Consideration must be given to the implications of unanticipated transmission delays or failures of the link Ea
90. quirements with respect to grounding of all equipment Many parts of this soft starter including the printed circuit boards operate at the line voltage DO NOT TOUCH Use only electrically insulated tools DO NOT touch unshielded components or terminal strip screw connections with voltage present Before servicing the soft starter Disconnect all power including external control power that may be present Place a DO NOT TURN ON label on all power disconnects Lock all power disconnects in the open position Install and close all covers before applying power or starting and stopping the soft starter Failure to follow these instructions will result in death or serious injury NOTE In this document the terms soft starter soft start controller and ATS48 controller are used interchangeably to refer to the same Altistart 48 Y Range device Altistart 48 Y Range Soft Start Controllers Section 1 Quick Start Procedure S 1A37491 01 2010 With the power removed make the following connections to the ATS48 soft starter a Connect the 115 V or 230 Vac control supply to CL1 and CL2 b Connect the power supply to 1 L1 3 L2 and 5 L3 c Connect the motor to 2 T1 4 T2 and 6 T3 NOTE If a shorting bypass contactor is used connect it between L1 L2 and L3 on the line side supply terminals and A2 B2 and C2 of the ATS48 soft starter Refer to Figure 1 and to the wiring diagrams in Appendix
91. relay R3 Scaling of the analog output Configuration of the analog outpu 5 4 Ei Parameters First level parameter settings first level parameters Typically locked out features 2002 2010 Schneider Electric All Rights Reserved 1 Second level parameters depend upon choice of Altistart 48 Y Range Soft Start Controllers Section 7 Programming Assignment of analog output AO i Qo ids i Qo SE na Not assigned T L 1A Forced freewheel stop T LIE External fault T L IH Motor preheating T 1 L IL Force to local control mode T Can be Qo LT Inhibits all protection selected T 1 E qE Reset after motor thermal fault T 1 L IE Activation of the cascade function T 1 E Ir Reset after faults are cleared T L E Activation of second set of motor parameters ENSE RN NUN Parameters are visible if Qo LIH is assigned Lo I P i o L D2 F So Fault relay X Isolation relay 4 BdEp9 rdi o GEN J l l Not assigned no T ll Thermal alarm motor 1 A T l Motor powered rn 1 Can be eo selected Motor current alarm A uS Motor underload alarm HE 1 PTC probe alarm APL T li Second set of motor parameters activated A 5 2 N d ot assigne
92. reshold setting of parameter LOC for longer than the time parameter tOL is set for one of the following occurs e ALA an alarm activates internal bit and configurable logic output e dEF the soft starter will not run and the OLC error code displays e OFF no protection l 300 hysteresis LOC 50 6 gt t detection OIL Lot Current overload threshold 50 to 300 of I 80 This parameter is not available if OIL is set to OFF LOC can be set from 50 to 300 of the nominal motor current EOL Current overload time 0 1 to 60 s 10s This parameter is not available if OIL is set to OFF Time delay tOL activates when the motor current rises above threshold LOC It resets to zero if the current falls below this LOC threshold again by at least 10 hysteresis PHr Protection against line phase inversion 321 123 or no no If the line phases are not in the order configured the soft starter locks and displays the PIF error code This parameter tells the soft starter the line phase order e 321 reverse L3 L2 L1 e 123 forward L1 L2 L3 no not monitoring Ehs5 Time before starting 0to 999 s 2s This parameter avoids starts in quick succession which may overheat the motor The time delay starts when the motor changes to freewheel mode In 2 wire control the motor is restarted after the time delay if the RUN command input is still act
93. ror code e Check the mechanism for wear mechanical play lubrication and blockages EEF External fault e Check the value of the tLs setting in the PrO menu page 51 Make sure the soft starter and motor are sized properly for the load and application e Check the mechanism for wear mechanical play lubrication and blockages ns Current overload e Check the value of parameters LOC and tOL in the PrO menu page 52 e Check the mechanism for wear mechanical play lubrication and blockages Make sure the soft starter and motor are sized properly for the load and application x Motor thermal fault e Check the value of parameter tHP in the PrO menu page 51 and that of parameter Iy in the GEI menu page 47 e Check the electrical isolation of the motor e Wait for the motor to cool before restarting e Check the mechanism for wear mechanical play lubrication and blockages OLE Motor thermal fault detected by the PTC probes Make sure the soft starter and motor are sized properly for the load and application e Check the value of the PtC setting in the PrO menu page 52 e Wait for the motor to cool before restarting e Check the hydraulic circuit ULF Motor underload e Check the value of parameters LUL and tUL in the PrO menu page 51 Locked rotor in steady state Lc E This fault is only active in steady state with soft starter bypass Check the mechanism for wear mechanical play lubrication and contactor It is detected if the curr
94. rter at the end of the starting phase This is not a programmable feature Relay R3 ml e no not assigned s Wl motor thermal alarm See page 39 e ml motor powered mu AIL motor current alarm threshold OIL and time tOL of PrO menu exceeded See page 52 e AUL motor underload alarm threshold LUL and time tUL of PrO menu exceeded See page 51 e APC motor PTC probe alarm See PtC on page 52 e AS2 second set of motor parameters activated See LIS on page 58 Analog output OCr no notassigned e OCr motor current AQ Je Otr motor torque e OtH motor thermal state e OCO power factor OPr active power Configuration of the analog output AO 020 420 020 O 4 fe 020 0 20 mA signal e 420 4 20 mA signal Scaling of the analog output 50 to 500 200 oer This parameter allows you to scale the analog output as a percentage of the nominal value of the parameter configured or if the parameter is power factor of 1 for the power factor 2002 2010 Schneider Electric All Rights Reserved 59 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 7 Programming 01 2010 Figure 29 Second Motor Parameters Menu St2 Nominal motor current On the next acceleration nc Current limit Immediately E Acceleration ramp time On the next acceleration Initial starting torque On the next acceleration Deceleration ramp time Threshold for changing to freewheel stop mode at the end o
95. s Reserved S 1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Section 1 Quick Start Procedure Section 1 Quick Start Procedure 2002 2010 Schneider Electric All Rights Reserved A WARNING DAMAGED SOFT STARTER EQUIPMENT Do not operate or install any soft starter that appears damaged Failure to follow these instructions can result in death serious injury or additional equipment damage 1 Before installing or storing the Altistart 48 ATS48 soft starter thoroughly inspect it according to the instructions in Receiving and Preliminary Inspection on page 11 a Verify that the soft starter catalog number printed on the label is the same as that on the packing slip and corresponding purchase order b Remove the ATS48 soft starter from its packaging and check that it has not been damaged during transit if any damage is found notify the carrier and your Schneider Electric representative 2 Install the ATS48 soft starter in accordance with the mounting ventilation and environmental requirements specified under Mounting on page 19 A DANGER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH Read and understand this manual before installing or operating the Altistart 48 ATS48 soft starter Installation adjustment repair and maintenance must be performed by qualified personnel e The user is responsible for compliance with all international and national electrical code re
96. sed When the starter is running it is not possible to select a different parameter to be displayed e Partial Locked Position Limited access to the SEL PrO and SUP menu parameters Pr N e Unlocked Position All parameters are accessible Any display restrictions to the starter by the access switch will still be in force once the remote keypad display has been disconnected from the controller even if power to the controller is cycled Figure 10 Remote Keypad Display Cable Assembly and Connectors ATS48 controller RJ 45 23 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 4 Mounting 01 2010 24 2002 2010 Schneider Electric All Rights Reserved S1A37491 Altistart 48 Y Range Soft Start Controllers 01 2010 Section 5 Wiring Section 5 Wiring Good wiring practice requires the separation of control circuit wiring from all power line and load wiring Power wiring to the motor must have the maximum possible separation from all other power wiring Do not run them in the same conduit This separation reduces the possibility of coupling electrical noise between circuits Installation Precautions Follow these precautions when installing the ATS48 controller A DANGER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH Read and understand this manual before installing or operating the Altistart 48 ATS48 controller Installation adjustment repair and mainten
97. see Table 18 on page 46 If no error code is displayed and the soft starter does not start e Check that the line supply is present on the control supply CL1 CL2 see page 35 e Check for the presence of the RUN STOP commands see Appendix A on page 79 When a condition requiring a power reset is detected the soft starter locks Reset and the motor switches to freewheel mode The following are signals that a condition requiring a power reset has been detected Relay R2 opens e After the soft starter locks Relay R1 opens e An error code flashes on the display e The last 5 error codes are stored and viewable with the PowerSuite software workshop Before restarting the soft starter e Remove the cause of the error see Table 26 e Disconnect and reconnect the control supply Table 26 Conditions Requiring a Power Reset Error Code Probable Cause Corrective Action Displayed IAF Internal analysis needed Disconnect and reconnect the control supply If the condition n y persists contact Schneider Electric product support Overcurrent Disconnect power to the soft starter then e impeding short circuit on soft starter output e Check the connecting cables and the motor isolation OCF internal short circuit e Check the thyristors e bypass contactor stuck e Check the bypass contactor for a stuck contact e soft starter is overloaded e Check the parameter value bSt in the menu drC page 55 Phase inversion P IF The line phase in
98. start A series of automatic attempts are made to restart the soft starter at intervals of 60 s Ifa restart has not been possible after 6 attempts the procedure is abandoned and the soft starter will not run until it is switched off then switched on again or reset manually see Hr 5 Detected Fault and Operating Condition Management on page 69 The following error codes permit this function PHF FrF CLF USF The soft starter fault relay remains activated if this function is active The run command must be maintained This function can only be used in 2 wire control e OFF Function inactive e On Function active Reset motor thermal state calculated by no YES n Ke the soft starter e no Function inactive e YES Function active 53 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 7 Programming 01 2010 Figure 27 Advanced Setting Menu drC Torque limit as a percentage of the nominal torque TG CIE IO Voltage boost level Oj CIE Tests on small motor Torque control Stator loss compensation OINO aO Deceleration gain Ua amp e e e elle Activation of the cascade function Se Line voltage to calculate power in kW S SH a all ON Ile Line frequency p T Reset kWh or the operating time le m us Return to factory settings LLL Parameters in menu The Advanced setting parameters can only be modified when the
99. tactor will be commanded to close The controller will continue to monitor the motor thermal state and provide motor overload protection Upon a stop command the SC contactor will open transferring the motor current to the SCRs to allow for controlled deceleration if desired The pilot relay SCA is required when the SC contactor coil exceeds the relay rating TS Transient Suppressors Transient suppression of all relay and contactor coils except ST is recommended to minimize the possibility of electrical interference with the controller electronics and to increase relay contact life RCR Run Command Relay Used in all non reversing logic optional in shunt trip for proper sequencing of contactor logic When energized RCR initiates the start sequence When de energized stopping is initiated Operator controls can be either on off selector switch HOA selector switch or start stop push buttons RCR remains energized during a fault condition Once the fault condition has been cleared RCR must be de energized by a stop command then re energized to restart the controller RFR Run Forward Relay Used for reversing applications only this coil duplicates the functionality of RCR for the forward direction and is interlocked with the RFR relay RRR ST Run Reverse Relay Shunt Trip Coil Used for reversing applications only this coil duplicates the functionality of RCR for the reverse direction and is interlocked w
100. tarter Invalid configuration EFI r PRU e Check the initial configuration The configuration loaded in the soft starter via the seriallinkis Loada compatible configuration incompatible Auto Reset Conditions Customer when an auto reset condition is detected the soft starter locks and the Configu rable motor switches to freewheel mode The soft starter will automatically restart when the fault has cleared The following are signals that an auto reset condition has been detected Relay R2 opens e If relay R1 is configured as an isolating relay it opens R1 remains closed if it is configured as a fault relay see page 59 The error code flashes on the display as long as the fault is present The last 5 error codes are stored and viewable with the PowerSuite software workshop Perform the following steps for any of the error codes listed in Table 28 before restarting the soft starter e Rectify the cause of the fault e n2 wire control maintain the run command on the RUN input NOTE The soft starter attempts to restart six times at 60 second intervals If the fault is still present at the 6th attempt it trips requiring a manual reset see Conditions Requiring Reset by a Repeated 2 times Run Command Input on page 71 If relay R1 is configured as a fault relay it opens 70 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Secti
101. ternal ambient temperature 0 e external ambient temperature ge ATS48 controller 20 S 1A37491 01 2010 Follow the instructions in this section in order to meet NEMA Type 1 IP23 degree of protection To help ensure adequate air flow inside the controller follow these guidelines Leave sufficient space around the controller see Figure 7 e Ensure sufficient ventilation If necessary install a cooling fan with filters Figure 7 Ventilation and Clearances 4 in 100 mm E E eo Ww 8 lt 40 C lt 40 C EON l4 z 4in z D e B dd bell 00mm On soft starters with a factory installed cooling fan the fan switches on automatically as soon as the heatsink temperature reaches 50 C It is switched off when the temperature drops to 40 C Table 11 Fan Flow Rates Part Number CFM m3 hour ATS48D32Y and D38Y 24 14 ATS48D47Y 48 28 ATS48D62Y to C11Y 146 86 ATS48C14Y and C17Y 235 138 ATS48C21Y to C32Y 476 280 ATS48C41Y to C66Y 1020 600 ATS48C79Y to M12Y 2040 1200 Follow the instructions in this section in order to meet NEMA Type 12 IP54 degree of protection Maintain clearances as shown in Figure 7 Do not use insulated or non metallic enclosures as they have poor thermal conduction Provide a stirring fan to circulate air inside the enclosure and to help prevent hot spots in the controller as shown in Figure 8
102. the capacitors must be located on the line side of the controller A separate contactor should be used to switch the capacitors off when the motor is off or during acceleration and deceleration Refer to bulletin 8638PD9603 ACAUTION IMPROPER WIRING HAZARD Do not connect power factor correction capacitors to the load side power circuit of the ATS48 controller Failure to follow these instructions can result in injury or equipment damage The ATS48 controller uses solid state power switches to control motor power When checking the condition of conductor or motor insulation do not connect the high potential dielectric test equipment or insulation resistance tester to the controller since the test voltages used may damage the controller Always disconnect the controller from the conductors or motor before performing such tests ACAUTION ATS48 CONTROLLER EQUIPMENT DAMAGE HAZARD Do not perform high potential dielectric tests on circuits while the circuits are connected to the ATS48 controller Any circuit requiring high potential dielectric tests must be disconnected from the controller prior to performing the test Failure to follow these instructions can result in injury or equipment damage The ATS48 controller contains electronic protection to detect and signal when the solid state switches have become inoperable Since the solid state switches may be incapable of completely blocking the motor power s
103. ting time delay not elapsed ACC acceleration in progress A dEC deceleration in progress rUn steady state operation brL braking in progress CLI soft starter in current limiting mode nSt force to freewheel stop by a logic input or the serial link ELA Error code for last detected fault see page 69 L FL If noerror codes have been saved the display shows n UF If faults have been inhibited the display shows n h 65 Altistart 48 Y Range Soft Start Controllers Section 7 Programming 66 S1A37491 01 2010 Table 25 Parameter Displayed Menu SUP Parameters continued Code Parameter Unit PHE Phase rotation direction as viewed from the soft starter e 123 forward L1 L2 L3 e 321 reverse L3 L2 L1 Cod Keypad display locking code enables the soft starter configuration to be protected using an access code password OFF no access locking codes e To lock access enter a code 2 to 999 The number displayed can be increased using the A key Now press ENT On appears on the screen to indicate that the parameters have been locked On a code is locking access 2 to 999 Tounlock access enter the code increasing the number displayed using the A key and press ENT The code remains on the display and access is unlocked until the next power down Parameter access will be locked again on the next power up e Ifan incorrect code is entered On appears on the display
104. to service Failure to follow these instructions can result in death serious injury or equipment damage For additional information refer to NEMA ICS 1 1 latest edition Safety Guidelines for the Application Installation and Maintenance of Solid State Control and to NEMA ICS 7 1 latest edition Safety Standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems The VW3G48101 remote keypad display can be mounted on the door of a wall mounted or floor standing enclosure The remote keypad display kit includes a seal for IP65 protection and a 9 82 ft 3 m cable with connectors Communication is via the RJ 45 Modbus connection on the starter see Figure 10 The remote keypad display has the same signaling display and configuration buttons as the controller s integral keypad display A switch to lock access to the parameters is located at the rear of the keypad display 2002 2010 Schneider Electric All Rights Reserved S 1A37491 01 2010 Altistart 48 Y Range Soft Start Controllers Section 4 Mounting Figure 9 Remote Keypad Display Front and Rear Views H Lat 3 characters e O OQ 2002 2010 Schneider Electric All Rights Reserved O Connector access switch AM The access switch on the remote keypad display is used as follows Locked Position D Only monitoring parameters can be acces
105. version does not conform to the PHr parameter setting Invert two line phases or set PHr to no in the Protection menu Disconnect and reconnect the control supply If the condition EEF Internal memory analysis needed persists contact the Product Support Group See page 73 for 2002 2010 Schneider Electric All Rights Reserved contact information 69 Altistart 48 Y Range Soft Start Controllers S1A37491 Section 8 Detected Fault and Operating Condition Management 01 2010 Conditions Requiring a Run When a condition requiring a run command reset is detected the soft starter Command Reset locks and the motor switches to freewheel mode The following are signals that a condition requiring a run command reset has been detected Relay R2 opens If relay R1 is configured as an isolating relay it opens The error code flashes on the display as long as the error is present The last 5 error codes are stored and viewable with the PowerSuite software workshop Do the following before restarting the soft starter e Rectify the cause of the error see Table 27 n2 wire control maintain the run command on the RUN input n 3 wire control initiate a new run command rising edge on the RUN input Table 27 Conditions Requiring a Run Command Reset Error Code Displayed Probable Cause Corrective Action e Revert to the factory setting in the drive menu drC CFF Invalid configuration on power up Reconfigure the soft s

Altistart® 48 Y-Range Soft Start Controllers

Contents

Download Pdf Manuals

Related Search

Related Contents

Altistart&reg; 48 Y-Range Soft Start Controllers

Contents

Download Pdf Manuals

Related Search

Related Contents

Altistart® 48 Y-Range Soft Start Controllers