ALTISTART® 48 Y-Range Soft Start Controllers Installation Guide

Section 1: Quick Start Procedure

⚠️ DANGER: HAZARDOUS VOLTAGE

Disconnect all power supplying this equipment prior to working on it. Failure to follow this instruction will result in death or serious injury.

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 9.

• 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 17.

3. 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 A beginning on page 73.

Figure 1: Power Block Diagram - Illustrates the connection of AC line supply to terminals 1/L1, 3/L2, 5/L3, the motor to terminals 2/T1, 4/T2, 6/T3, and the bypass/shorting contactor connections to A2, B2, C2.

Figure 2: Control Circuit Terminal Configuration - Shows the layout of control terminals including CL1, CL2 for control supply; PTC1, PTC2 for PTC probes; AO1, COM for analog output; LO1, LO2 for logic outputs; LO+, +24V for logic output power supply; LI3, LI4, RUN, STOP for logic inputs; R1A, R1C, R2A, R2C, R3A, R3C for relay outputs.

4. Set parameter IN (in the SEt menu, see page 41) 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 for the factory preset values. If the factory configuration is not suitable for your application, refer to "Programming" on page 37 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 control terminal to start the system.

Table 1: Factory Configuration

Section 2: Receiving and Handling

Introduction

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 ensure smooth rotation throughout the starting ramp without mechanical instability at the end of starting.

A microprocessor continuously monitors the motor and controller performance to provide maximum protection of the controller, motor, and driven machinery. A variety of starting and stopping modes are standard. A digital keypad display provides accurate controller setup and continuous 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.

Many option kits are available for the ATS48 controllers. Refer to Appendix C beginning on page 79.

Terminology

Some of the terms and acronyms used in this manual are defined in Table 2.

Table 2: Definition of Terms

Receiving and Preliminary Inspection

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 Square D / 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.

⚠️ CAUTION: EQUIPMENT DAMAGE HAZARD

Do not operate or install any controller that appears damaged. Failure to follow this instruction can result in injury or equipment damage.

Storing and Shipping

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.

Handling the Controller

Do not remove the ATS48 controller from the carton until it is at the final installation site. The carton provides protection and prevents 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:

• 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.
• In a 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 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.

⚠️ 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 this instruction can result in death or serious injury.

Figure 3: Hoisting the ATS48 Controller - Depicts a controller being lifted using a spreader bar attached to lifting holes on the top of the unit, with a maximum tilt angle indicated.

Section 3: Technical Data

Technical Characteristics

Tables 3 and 4 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 with a shorting/bypass contactor. The nominal motor current IN 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 -15%, 50 or 60 Hz)

Table 4: Severe Duty Application, 208 to 690 V Supply (+10% to -15%, 50 or 60 Hz)

Specifications

Table 5: Environmental Characteristics

Table 6: Electrical Characteristics

Table 7: Electromagnetic Compatibility (EMC)

Table 8: Short Circuit Protection Device (Type 1 Coordination)

Dimensions and Weights

Figure 4: ATS48D17Y–C66Y Dimensions - Shows a diagram with dimensions labeled 'a', 'b', 'c', 'e', 'G', 'H', '' for various ATS48 models.

Table 9: ATS48D17Y–C66Y Dimensions

Figure 5: ATS48C79Y–M12Y Dimensions - Shows a diagram with dimensions labeled 'a', 'b', 'c', 'e', 'G', 'H', '' for larger ATS48 models.

Table 10: ATS48C79Y–M12Y Dimensions

Serial and Model Numbers

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 - Illustrates the location of the serial number and model number on the controller's label.

Section 4: Mounting

Mounting Precautions

Follow these precautions when mounting the ATS48 controller:

• 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.

⚠️ DANGER: HAZARDOUS VOLTAGE

ATS48 controllers are open devices and must be mounted in a suitable enclosure. Electrical shock will result in death or serious injury.

• 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 controller.
• 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 19 to determine power dissipated.
• 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.

⚠️ CAUTION: CONTROLLER OVERHEATING

• Mount the ATS48 controller within ±10° of vertical.
• Do not locate the controller near heat radiating elements.
• Electrical current through the controller will result in heat losses that must be dissipated into the ambient air immediately surrounding the controller. To prevent thermal fault or equipment damage, provide sufficient enclosure cooling and/or ventilation to limit the ambient temperature around the controller.

Failure to follow this instruction can result in injury or equipment damage.

Soft Starter Ventilation

On soft starters fitted with a 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

Mounting in a General Purpose Metal Enclosure

Follow the instructions in this section in order to meet NEMA Type 1 (IP23) degree of protection. To ensure adequate air flow inside the controller, follow these guidelines:

• Leave sufficient space around the controller (see Figure 7).
• Ensure sufficient ventilation. If necessary, install a cooling fan with filters.

Figure 7: Ventilation and Clearances - Shows a diagram indicating required clearances around the soft starter for ventilation, typically 4 inches (100 mm) on sides and top/bottom.

Mounting in a Dust and Damp-Proof Metal Enclosure

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 prevent hot spots in the controller, as shown in Figure 8. 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 IN by 2% per °C for temperatures above 40 °C if a shorting/bypass contactor is not used.

Figure 8: Ventilation for Dust and Damp-Proof Enclosure - Illustrates an enclosure with a stirring fan to circulate air, showing internal (i) and external (e) ambient temperatures.

Thermal Considerations for Sizing Enclosures

When mounting the ATS48 soft starter in an enclosure, use the enclosure 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

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.

Remote Keypad Display (If Used)

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.

Figure 9: Remote Keypad Display, Front and Rear Views - Shows the front of the display with 3-character segments and the rear with a connector access switch.

The access switch on the remote keypad display is used as follows:

• Locked Position: Only monitoring parameters can be accessed. When the starter is running, it is not possible to select a different parameter to be displayed.
• Partial Locked Position: Limited access to the SEt, PrO, and SUP menu parameters.
• Unlocked Position: All parameters are accessible.

Any display restrictions to the starter by the access switch will still be in force once the controller has been disconnected and even if power to the controller is cycled.

Figure 10: Remote Keypad Display Cable Assembly and Connectors - Illustrates the connection between the ATS48 controller's RJ-45 port and the remote keypad display cable.

Section 5: Wiring

Installation Precautions

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.

Follow these precautions when installing the ATS48 controller:

⚠️ DANGER: HAZARDOUS VOLTAGE

• Read and understand this manual in its entirety before installing or operating ATS48 controllers. Installation, adjustment, repair, and maintenance of these controllers must be performed by qualified personnel.
• The user is responsible for conforming to all applicable code requirements with respect to grounding all equipment. See Figures 11–15 on pages 25–29 for grounding points.
• Many parts in this controller, including printed wiring boards, operate at line voltage. DO NOT TOUCH. Use only electrically-insulated tools while making adjustments.
• DO NOT touch unshielded components or terminal strip screw connections with voltage present.
• Before installing or servicing the controller:
  • Disconnect all power.
  • Place a "DO NOT TURN ON" label on the controller disconnect.
  • Lock the disconnect in the open position.
• Install all covers before applying power or starting and stopping the controller.

Failure to follow this instruction will result in death, serious injury, or equipment damage.

• Voltage and frequency specifications for the input line must match the controller configuration.
• A disconnect switch must be installed between the input line and the controller.

⚠️ DANGER: HAZARDOUS VOLTAGE

The solid state switches of the ATS48 controller's power circuit do not provide complete isolation from the AC line. Due to leakage currents through the solid-state switches, hazardous voltages can be 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. Electrical shock will result in death or serious injury.

• 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.
• 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 14.

⚠️ WARNING: OVERCURRENT DEVICES MUST BE PROPERLY COORDINATED

An OCPD must be installed on the line-side of the ATS48 controller to achieve published short-circuit withstand ratings. Do not exceed the maximum OCPD ratings shown in Table 8 on page 14. 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 14. Failure to follow this instruction 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, 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.

⚠️ CAUTION: EQUIPMENT DAMAGE HAZARD

Do not connect power factor correction capacitors to the load-side power circuit of the ATS48 controller. Failure to follow this instruction 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.

⚠️ CAUTION: 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 this instruction can result in injury or equipment damage.

The ATS48 controller contains electronic protection to detect and signal failure of the solid-state switches. Since the solid-state switches may be incapable of completely blocking the motor power should a fault occur, 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 controller power circuit in the event of a controller fault. The isolation device must be capable of interrupting motor locked rotor current.

Refer to Appendix A beginning on page 73 for typical circuit diagrams that display the logic controlling the isolation device via the fault relay.

⚠️ CAUTION: MOTOR OVERHEATING

Failure of the solid-state switches on the ATS48 controller can cause single-phase operation of the motor.

• Use an 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.
• Connect the fault relay of the controller to open the isolation device in the event of a controller fault.

Failure to follow this instruction can result in injury or equipment damage.

⚠️ WARNING: BRANCH CIRCUIT CONDUCTOR HAZARD

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 79 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.

Failure to follow this instruction can result in death or serious injury.

General Wiring Practices

When wiring ATS48 controllers, follow the wiring practices required by national and local electrical codes. In addition, follow these guidelines:

• Use metallic conduit for all controller wiring. Do not run control and power wiring in the same conduit.
• Separate metallic conduits carrying power wiring or low-level control wiring by at least 3 in (80 mm).
• 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 (305 mm).
• 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 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 -15%) for standard controllers.

Power Connections

Table 13: Wire Size and Tightening Torque

¹ Power terminals are suitable for use with 75 °C rated conductors; copper only.

² Requires user supplied lug.

Figure 11: Power Connections ATS48D17Y to C11Y - Shows a wiring diagram for smaller ATS48 models, illustrating connections for L1, L2, L3, T1, T2, T3, A2, B2, C2 to a motor (M).

Figure 12: Power Connections ATS48C14Y to C17Y - Shows a wiring diagram with dimensions for ATS48C14Y to C17Y models.

Figure 13: Power Connections ATS48C21Y to C32Y - Shows a wiring diagram with dimensions for ATS48C21Y to C32Y models.

Figure 14: Power Connections ATS48C41Y to C66Y - Shows a wiring diagram with dimensions for ATS48C41Y to C66Y models.

Figure 15: Power Connections ATS48C79Y to M12Y - Shows a wiring diagram with dimensions for ATS48C79Y to M12Y models.

Control Connections

Although all control inputs and outputs of the controller are isolated from the input lines, follow these control wiring precautions:

• 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 mm²)
  • Maximum tightening torque: 3.5 lb-in. (4 N·m)
• On ATS48C17Y to ATS48M12Y the protective cover must be removed in order to access the control terminals.

Figure 16: Control Terminals - Depicts the layout of control terminals on the ATS48 controller, including relay outputs, logic inputs/outputs, analog output, common, PTC probes, and an RJ-45 connector.

Table 14: Control Terminal Blocks

Section 6: Application and Protection

Soft Starter Applications

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.

• Standard Duty Applications: In standard duty applications, the ATS48 soft starter is designed to provide:
  • Starting at 400% of IN for 23 seconds, or 300% of IN for 46 seconds, from a cold state.
  • Starting at 400% of IN for 12 seconds, or 300% of IN for 23 seconds, with a load factor of 50% and 10 starts per hour or an equivalent thermal cycling.
  • The motor thermal protection conforms to Class 10 overload protection.
• Severe Duty Applications: In severe duty applications, the ATS48 soft starter is designed to provide:
  • Starting at 400% of IN for 48 seconds, or 300% of IN for 90 seconds, from a cold state.
  • Starting at 400% of IN 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.

Reduced Torque

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 32 shows the speed/torque characteristics as a function of the supply voltage.

Figure 17: Torque as a Function of Applied Voltage - Graph showing torque vs. % rated speed, with curves for Vn, 0.85Vn, and 0.6Vn, illustrating how torque decreases with reduced voltage.

Figure 18: Torque as a Function of Starting Current - Graph showing torque vs. % rated speed, illustrating starting current Id and current limit Id1 during soft start.

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 Td1.

INTELE™ Braking

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:

• 4-pole or 6-pole motors only
• motor slip is less than or equal to 3%

The formula for calculating braking time is: t(sec) = WK² x rpm / (308 x (TFLT x 0.40)), where WK² is the connected motor load inertia (lb-ft²), rpm is the change in rpm or synchronous speed, and TFLT is the Full Load Torque (lb-ft). The calculated value must be equal to or less than 40.

Motor Protection and Diagnostics

The ATS48 controller provides state-of-the-art 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 fault status codes. The controller memory registers and maintains the previous 5 faults, 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.

Thermal Overload Protection

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 each 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 - Graph showing time vs. I/IN ratio, illustrating pre-alarm and fault trip points for T1 and T2 thermal models.

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. The various thermal overload protection classes are defined to meet the standards of IEC 60947-4-2 for starting from both cold and hot states. 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 - Graph showing time (s) vs. I/IN ratio, illustrating trip times for Class 2, 10A, 10, 15, 20, 25, 30 protection classes during cold starts.

Table 15: Cold Start Trip Time

Figure 21: Hot Start Curves - Graph showing time (s) vs. I/IN ratio, illustrating trip times for protection classes during hot starts.

Table 16: Hot Start Trip Time

Motor Thermal Protection with PTC Probes

PTC 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:

• To stop the machine in the event of a fault 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.

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.

Section 7: Programming

Programming and Setup

⚠️ 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.

Failure to follow this instruction can result in death, serious injury, or equipment damage.

If starting the soft starter from line power, limit operations to the duty cycle ratings described on page 31. Use inputs LI1 to LI4 to control the soft starter.

When changing the factory configuration, record your parameter settings in the Factory Settings table beginning on page 69.

When first commissioning an ATS48 controller on a 60 Hz system, perform a factory parameter reset (see FCS on page 50).

Programming the ATS48 controller is simplified by internal sequence selections and interlocks. For ease of setup, Square D recommends accessing the menus in the following order:

1. IO – 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 69–72 to record your settings.

Display Unit and Programming

Figure 22: Display Functions - Shows the controller's display interface with navigation buttons (ESC, ENT, Up/Down arrows) and their functions.

NOTE: Pressing Up or Down arrows does not store the choices. To store the displayed choice, press ENT. 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.

Table 17: How to Read Displayed Numbers

Menus

Menus are accessible in the order shown in Figure 23.

Figure 23: Accessing Menus - Flowchart showing the navigation path through the main menus (XXX, SEt, PrO, drC, IO, St2, COP, SUP).

Figure 24: Accessing Parameters - Illustrates how to navigate within a menu to select and modify a parameter value.

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.

Table 18: Soft Starter Status Codes

Table 18 also lists monitoring parameters selected by the user (SUP menu), with factory setting as motor current.

Figure 25: Settings Menu (SEt) - Overview of parameters within the Settings menu, including IN, ILt, ACC, tq0, StY, dEC, EdC, brC, EbA.

Table 19: Settings Menu (SEt) Parameters

* 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.

Figure 26: Protection Menu (PrO) - Overview of parameters within the Protection menu, including tHP, ULL, LUL, tUL, tLS, OIL, LOC, tOL, PHr, tbS, PHL, PtC, ArS, rtH.

Table 20: Protection Menu (PrO) Parameters

⚠️ CAUTION: UNINTENDED OPERATION

• The factory configuration of a monitoring alarm (ALA) indicates the presence of a fault but will not directly protect the installation.
• When using parameter ArS, ensure that an accidental start will not endanger personnel or equipment in any way.

Failure to follow this instruction can result in death or serious injury.

Figure 27: Advanced Setting Menu (drC) - Overview of parameters within the Advanced Setting menu, including tLI, bSt, SSt, CLP, LSC, tIG, CSC, ULn, FrC, rPr, FCS.

Table 21: Advanced Setting Menu (drC) Parameters

⚠️ CAUTION: NO BRAKING AND LIMITED STOPPING

With parameter dLt, only freewheel type stopping is possible: Cascading is not possible, Preheating is not possible. This limitation can result in injury.

Figure 28: I/O Menu (IO) - Overview of parameters for assigning logic inputs, logic outputs, relay outputs, and analog output.

Table 22: I/O Menu (IO) Parameters

Figure 29: Second Motor Parameters Menu (St2) - Overview of parameters for configuring a second motor or a second set of parameters.

Table 23: Second Motor Parameters Menu (St2) Parameters

Figure 30: Communication Menu (COP) - Overview of parameters for communication settings, including Add, tbr, FOr, tLP, PCt.

Table 24: Communication Menu (COP) Parameters

⚠️ WARNING: LOSS OF COMMUNICATION CAN CAUSE LOSS OF PROTECTION

When using parameter tLP, ensure that the time set will not interfere with the safe operation of the machine. Failure to follow this instruction can result in death or serious injury.

Figure 31: Parameter Displayed Menu (SUP) - Lists parameters that can be displayed, such as COS, tHr, LCr, rnt, LPr, Ltr, LAP, EtA, LFt, PHE, COd.

Table 25: Parameter Displayed Menu (SUP) Parameters

Figure 32: Compatibility - Table showing compatibility between various functions like Soft stop, INTELE braking, Thermal protection, etc.

Section 8: Fault Management

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.

Soft Starter Does Not Start, No Fault Displayed

Determine whether or not the code displayed corresponds to the normal state of the soft starter (see Table 17 on page 38).

If no fault is displayed and the soft starter does not start:

• Check that the line supply is present on the control supply CL1/CL2 (see page 30).
• Check for the presence of the RUN/STOP commands (see Appendix A).

Non-Resettable Faults

When a non-resettable fault appears the soft starter locks and the motor switches to freewheel mode.

The following are signals that a non-reset fault has occurred:

• Relay R2 opens.
• After the soft starter locks, Relay R1 opens.
• The fault code flashes on the display.
• The last 5 faults are stored and viewable with the PowerSuite software workshop.

Do the following before restarting the soft starter:

• Remove the fault cause(s), see Table 26.
• Disconnect and reconnect the control supply.

Table 26: Non-Reset Fault Correction

Resettable Faults When Causes Disappear

When a resettable fault appears the soft starter locks and the motor switches to freewheel mode.

The following are signals that a resettable fault has occurred:

• Relay R2 opens.
• If relay R1 is configured as an isolating relay, it opens.
• The fault code flashes on the display as long as the fault is present.
• The last 5 faults are stored and viewable with the PowerSuite software workshop.

Do the following before restarting the soft starter:

• Remove the cause of the fault, see Table 27.
• In 2-wire control, maintain the run command on the RUN input.
• In 3-wire control, initiate a new run command (rising edge) on the RUN input.

Table 27: Resettable Fault Correction

Auto-Reset Faults (Customer Configurable)

When an auto-reset fault appears the soft starter locks and the motor switches to freewheel mode. When an auto-reset fault occurs, the soft starter will automatically restart when the fault has cleared.

The following are signals that an auto-reset fault has occurred:

• Relay R2 opens.
• If relay R1 is configured as an isolating relay, it opens. R1 remains closed if it is configured as a fault relay, see page 53.
• The fault code flashes on the display as long as the fault is present.
• The last 5 faults are stored and viewable with the PowerSuite software workshop.

In 2-wire control, perform the following steps for any of the faults listed in Table 28 before restarting the soft starter:

• Remove the cause of the fault.
• 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 "Manual-Reset Faults" on page 65). If relay R1 is configured as a fault relay it opens. The run command must be maintained.

Table 28: Auto-Reset Fault Correction (2-wire control)

For any of the faults listed in Table 29 perform the following steps before restarting the soft starter:

• Remove the cause of the fault.
• In 2-wire control, maintain the run command.

Table 29: Auto-Reset Fault Correction

If the automatic restart function is not selected, see "Manual-Reset Faults" below for the indication of these faults and the restart instructions.

Manual-Reset Faults

When a manual reset fault appears, the soft starter locks and the motor switches to freewheel mode.

The following are signals that a manual-reset fault has occurred:

• Relay R2 opens.
• Relay R1 opens.
• The fault code flashes on the display as long as the fault is present.
• The last 5 faults are stored and viewable with the PowerSuite software workshop.

Perform the following steps before restarting the soft starter:

• Remove cause of the fault.
• In 2-wire and 3-wire control, initiate a new run command (rising edge) on the RUN input to reset the fault.

NOTE: A reset will not take place on a run command if LI is assigned to the fault reset (LIr) function. In 2-wire and 3-wire control, initiate another new run command (rising edge) on the RUN input to reset the fault.

Table 30: Manual-Reset Fault Correction

Reset Faults Using a Logic Input

If a logic input LI is configured to reset motor thermal fault, LIt, or any other resettable fault, LIr, for the motor to restart, the following conditions must be met:

• The soft starter must send a pulse on logic input LI.
• In 2-wire control, the run command must be maintained on the RUN input.
• In 3-wire control, a new run command (rising edge) must be initiated on the RUN input.

Troubleshooting Procedure

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 68 and use it to record the controller, motor, and peripheral equipment nameplate data.

Technical Support

For more information, call, fax, or write:

Square D / Schneider Electric Technical Support
8001 Highway 64 East
Knightdale, NC 27545-9023
Telephone: 919-266-8600 or 1-888-SQUARED (1-888-778-2733)
Fax: 919-217-6508
e-Mail: drivespsg@squared.com

ATS48 Troubleshooting Sheet

When requesting after-sales service, it is important to disclose all conditions under which the Square D / Schneider Electric equipment currently operates. This will help in diagnosing the system quickly. FAX to: Technical Support @ 919-217-6508

DATE: CONTACT NAME: COMPANY: ADDRESS: CITY: STATE: PHONE: FAX:

SOFT START CONFIGURATION PART NUMBER: ATS48 APPLICATION/EQUIPMENT DESIGNATION:

SERIAL NUMBER: 6W-

MOTOR NAMEPLATE DATA

HORSEPOWER: SERVICE FACTOR: MOTOR CABLE TYPE: VOLTAGE (3 PHASE): MOTOR TYPE/DESIGN: FREQUENCY: POLES: FLA: NEMA A NEMA B NEMA C NEMA D APPROXIMATE CABLE LENGTH (IN FEET):

POWER SOURCE AND ENVIRONMENT

VOLTAGE BETWEEN L1 AND L2: SERVICE TRANSFORMER RATING: VOLTAGE BETWEEN L2 AND L3: VOLTAGE BETWEEN L3 AND L1: KVA, % Z FREQUENCY: 60HZ OR 50 HZ AMBIENT TEMPERATURES: MIN °C (°F) MAX °C (°F) HUMIDITY: ALTITUDE IF GREATER THAN 3300 FEET ABOVE SEA LEVEL, SPECIFY: FT

SOFT START FAULT CODES

REFER TO TABLES 28 THROUGH 33 FOR POSSIBLE CAUSES & CORRECTIVE ACTION

NON-RESET FAULTS

INF – INTERNAL FAULT OCF - OVERCURRENT PIF – PHASE INVERSION EEF – INTERNAL MEMORY

AUTO-RESET FAULTS (CUSTOMER CONFIGURABLE)

PHF – LOSS OF PHASE OR LOSS OF MOTOR PHASE FRF – LINE FREQUENCY (OUT OF TOLERANCE) USF – POWER SUPPLY CLF – CONTROL LINE FAILURE (CL1/CL2)

MANUAL RESET FAULTS

SLF – SERIAL LINK FAULT ETF – EXTERNAL FAULT STF – EXCESSIVE STARTING TIME OLC – CURRENT OVERLOAD OLF – MOTOR THERMAL FAULT OHF – STARTER THERMAL FAULT OTF – MOTOR THERMAL FAULT VIA PTC PROBES ULF – MOTOR UNDERLOAD LrF – LOCKED ROTOR (IN STEADY STATE)

RESETTABLE FAULTS WHEN CAUSES DISAPPEAR

CFF – INVALID CONFIGURATION (POWER UP) CFI – INVALID CONFIGURATION (COMM)

DETAILED DESCRIPTION OF PROBLEM (ATTACH WIRING DIAGRAM/SCHEMATICS IF APPLICABLE):

Appendices

Appendix A: Recommended Wiring Diagrams

Figures 33–35 illustrate circuit diagrams for typical non-reversing and reversing applications in 2-wire and 3-wire control. The recommended circuit diagrams include SCR fault isolation for optimal protection of the motor, driven machinery, and operating personnel.

Table 31: Description of Logic for Recommended Wiring Diagrams

Figure 33: Nonreversing with Shunt Trip Fault Isolation - Illustrates a wiring diagram for a non-reversing application using a circuit breaker with a shunt trip coil for fault isolation.

Figure 34: Nonreversing with Isolation Contactor - Illustrates a wiring diagram for a non-reversing application using an isolation contactor for fault isolation.

Figure 35: Reversing with Isolation Contactors - Illustrates a wiring diagram for a reversing application using isolation contactors for fault isolation.

Appendix B: Recommended Component Lists

Table 32: Suggested Components for Standard Duty Applications - Lists suggested components like induction motors, ATS48 controllers, contactors, fuses, and fuse blocks for various motor horsepower ratings.

Table 33: Additional Suggested Components for Standard Duty Applications

¹ All coils are selected for 120 V, 60 Hz operation. Refer to the Square D Digest for additional coil voltages or auxiliary contact configurations. One block may be added to each contactor.

² Power terminals are not included with LC1-F contactors. Refer to the latest editions of Square D / Schneider Electric's full line product catalogs for additional ordering information.

³ The use of transient suppressors across all contactor coils is recommended. Refer to the latest editions of Square D / Schneider Electric's full line product catalogs for selection of transient suppressors.

⁴ 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.

⁵ 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.

⁶ Reversing contactors for C11 through M12 controllers must be assembled from components. Parts quantities for a basic contactor assembly, minus the power connection links and terminals, are indicated before each part number. Refer to the latest editions of Square D / 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.

⁷ 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.

⁸ The molded case switches and circuit breakers selected require the addition of operator mechanisms to allow operation from the exterior of an enclosure. Refer to the latest editions of Square D / 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.

⁹ 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.

¹⁰ 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.

Appendix C: Options and Accessories

Tables 34–36 show the accessories available for ATS48 soft start controllers.

Table 34: Documentation

Table 35: Remote Keypad Display

Table 36: Protective Covers for Power Terminals

NOTE: The ATS48 controller has 9 unprotected power terminals.

PowerSuite Advanced Dialogue Solutions

PowerSuite solutions are compatible with software version 1.30, build 5.

Table 37: Pocket PC/PDA Kits

Table 38: PowerSuite Software for Personal Computers

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 Square D / Schneider Electric Distributor or Square D / Schneider Electric Customer Service Representative at 919-266-8666 for availability.