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1. FUI FU2 BEE EE TEX I l r ys tes pee 7 l DEO enr o EG I I I A d DOOS I I Ai Bi Ci it 342 543 C 500V 120V I I L L I KM3 J KM3 KM3 F1 T TY T 3 D FAULT L l r TYPICAL RiB 510 ON TRIP 1 I I l POWER d 50110 STATE t A TR RELAY l POLE OVERLOAD RELAY I l l l l l A2 B2 C2 21 4 T2 6TSSTOP RUN LI PL TS1 T 9 de CB SHUNT l l Dire SEKE I I gt M TRIP COIL LE gt EE dak 2 I 1 j i STOP START i a dj 1 RUN OR MOTOR GFR ed na RUN COMMAND Duci Se a VEE RELAY EE ER OFF ON 1 A O Control circuit connected for 460 V operation Reconnect as required for other voltages we i Shorting contactor terminals not provided OR on D17 D22 D32 OR D38 controllers SHORTING f 1 d Uomo qu eR is DEE NE CONTACTOR 3 For shorting contactor operation with D47N 1 1 i 4 PILOT RELAY hrough M12N controllers add KM3 with 2 associated control circuit i j RCR 1 KM3A 4 Relay contact located on ATS controller a i te AAA RN AE EE RERO NE SHORTING E CONTACTOR G Located at motor Jumper if switch not present 5 Use RCR relay logic for ATS 2 wire or 3 wire control when using shorting contactor DD n hiba mwa MAMBA Sna ama EE POWER ON
2. gt o gt Power Poles 9 n g E 5 H E sre IH sire Es Firing ee ee ee Board FSI E ER e e e II II I Filter II LII I Board VT UT Figure 53 ATS46C41 C48 C59 C66 C79 M10 M12 The SCR power pole assembly consists of the power pole the firing interface board and two thermal switches for ATS46C41 through M12N controllers The power pole consists of two SCRs within a heatsink The heatsink is tightened to provide balanced heat and current transfer within the assembly The power pole interface board and thermal switches are available as individual parts Pre mounted thermal switches are provided with the replacement power pole NOTE SCRs are not available for individual replacement Replacement of a single SCR through disassembly of the power pole will void the product warranty The ATS46C41 through M12 controllers use a firing interface board Each SCR pole requires one interface board Replace the board if there is visible damage to any of the components following an SCR failure The replacement power pole assembly does not include an interface board Reuse the original interface board unless it is damaged or order a replacement interface board 73 Chapter 6 Servicing the Controller Replacing the Control Module Firing Interface Board Replacement 74 VD0C32S301B June 1998 Refer to page 68 for SCR testing in
3. END TS2 START UP T 3 A OW sHoRTING Control circuit connected for 460 V operation A o JL o e KMS3A Hg 0 CONTACTOR Reconnect as required for other voltages 3 dp vi i PILOT RELAY RENTREE Shorting contactor terminals not provided on D17 D22 D32 KM3A ee or D38 controllers l e 7 OO SHORTING Nu CU E en ii en en e a contactor For shorting contactor operation with D47 through M12N uU d controllers add KM3 with associated control circuit j See od E rs bo Relay contact located on ATS controller NEM A IE Du ce a eee p AR R K Se RA eer 4 POWERON G Located at motor Jumper if switch not present PAP FR P Cs For D47 through C11 controllers using a shorting contactor mes pilot relay KM3A is not required Substitute coil of KM3 contactor AA RE E RES A ARS icis 4 w EE EI FAULT in place of KM3A pilot relay REA Set RFR time slightly longer than the expected deceleration Da yo ji time from rated forward speed to zero speed i uri LE GE u ce RE bi TUN TOWARD M 1 TL Set RRR time slightly longer than the expected deceleration KM2 Li REMMA e time from rated reverse speed to zero speed D rs TER MH H HHH ss ces a ESA RUN REVERSE NI Pr OS Cs Remove these contacts to inhibit direction reversal without 7 User supplied first depressing STOP pushbutton 1 2 WIRE CONTROL W AUTO
4. 36 Stall and Steady State Protection 37 Protection from Line Faulis 38 CONTROLLER I O CONFIGURATION 38 Faults ISO Contactor Control Relays 38 End of Start Up Relay i cL e ed ERR ne AERE xr de 38 Logic OUtpUt em A eta ee ea Ye ERAS 38 Analog O tp t 22 IE EE OE AA na LAUR 2 he 39 Logic est wots ytd Ye t DV ME SNO EN 39 DISPLAYOFMOTORVALUES 39 I ALTISTART 46 Soft Start Controller Contents CHAPTER 4 CONTROLLER SETUP AND OPERATION CHAPTER 5 FAULT MANAGEMENT CHAPTER 6 SERVICING THE CONTROLLER Bulletin No VD0C32S301B June 1998 FACTORY PRESETS annie EE RE ER ee ie Gd Bik DET Ros teen 40 USING THE KEYPAD 5 A EC P acc nn te fe rom kee ae 40 Selecting a Menu Level 41 Operating the Pushbuttons 42 ADJUSTING CONTROLLER SETTINGS 43 Control Parameters su see ka 43 Parameter Flowcliatts x ER Rex ERR RE Rx x eR eral 45 Setting the Motor Current 51 Setting the Current Limit 51 Advanced Acceleration Ramp Adjustmen
5. 19 Logic Input ORE Lie Rr Rod Waran e 21 Logic QUIDUTS EE SE DER eas as e e J J Ped a ad 21 Analog Output 3 eun peck dened dida ele hae 21 REMOTE MOUNTING KEYPAD 22 CONTROL CIRCUITDIAGRAMS 22 RECOMMENDED COMPONENT LIST 26 SOFT STARTAPPLICATION 30 Standard Duty Applications 30 Heavy Duty Applications 30 Reduced Torque ir RR PRU ee REN VR BOE N 30 MODES OF STARTING ss er de IEEE denk X M RE ne Zele a 31 Acceleration Ramp Ek ak kk ee 31 Mee EA d eh eh ele ele ons RO n E hee Se Rae NE 32 Current Limite ees ea n y n Y ete ped ey dds WAV W w n AW 32 Voltage Boost a xaza HAW Ay k e ae l eed W GE A ava A 32 MODES OF STOPPING als xw wl hal a lal eem 32 Deceleration Ramp kk kak kk kk kk kk kk kk kk kK eens 32 Infele Brakirig uz EE RR paki lak Ra a de dates oba A l li la kav RE eat 33 MOTOR PROTECTION AND DIAGNOSTICS 33 Thermal Overload Protection 33 Excessive Cycling Prevention
6. E Case to heatsink connection Figure 50 SCR Connections When replacing SCRs damaged from exposure to excessive current or voltage e g short circuit or lightning strike it is good practice to replace the current measurement board and filter card for the replaced poles 1998 Square D All Rights Reserved VD0C32S301B June 1998 Filter Card Replacement Thermal Switch and Fan Replacement 1998 Square D All Rights Reserved Chapter 6 Servicing the Controller Replacing the Control Module For D17 through C14 controllers there is one filter card per unit mounted below the L1 L2 L3 connections For C17 through C32 controllers there are three filter cards one mounted to the bus bar on each phase To replace the filter card on D47 through C14 controllers follow these steps 1 Disconnect electrical connections from the board Note the position and color of each wire for reassembly 2 Disconnect power straps to SCRs as needed to access filter card 3 Using a flat blade screwdriver remove the filter card mounting screws e Removing the bus wiring may facilitate the removal of the filter card To access the filter card in D47 through C14 controllers only follow these steps 1 Take out the top two front cover screws See Figure 47 on page 68 2 Take out the four screws from the bottom cover of the controller 3 Disconnect T1 T2 and T3 from SCR 4 Pull the bottom plastic end cap out 5 Slide
7. SCRs Current measurement board Filter card Control power transformer Fanand thermal switches on models rated 72 A and above Figures 46 47 and 48 show available replacement parts Table 19 on page 66 lists catalog numbers p m Cover top Control Power Filter Card Transformer N i 2 io ze gt ya SIA Figure 46 ATS46D17 D22 D32 and D38 Controllers Em Cover top Side Panel Control Power Transformer Fan Thermal Switch Heatsink Thermal Switch Current Measurement Board Plastic Cover bottom Figure 47 ATS46D47 D62 D75 D88 C11 and C14 Controllers 1998 Square D All Rights Reserved VD0C32S301B June 1998 SCR Replacement 1998 Square D All Rights Reserved Chapter 6 Servicing the Controller Replacing the Control Module Fan House Screws Fan Assembly Control Power Transformer Current Measurement Board Fan Thermal Switch 6 es elle Heatsink Thermal Switch SCRs 1 Filter Cards o o 1 Two per phase for ATS46C32 One per phase for ATS46C17 to C25 Figure 48 ATS46C17 C21 C25 and C32 Controllers When an SCR fails the ATS46 controller will not attempt to start the motor Upon a start command a device with a failed SCR immediately shows a phase fault or internal fault code A DANGER
8. O For D47 through C11 controllers using a shorting contactor pilot relay KM3A is not required Substitute coil of KM3 User supplied in pl 1 i contactor in place of KM3A pilot relay 2 WIRE CONTROL W AUTO 2 WIRE CONTROL W O AUTO 3 WIRE CONTROL pow DEE TREE Oe we q aa ADEL er Ne 1 EV q OS RS Ke d i ON HAND AUTO e 9 j STOP START j 0 11 i I 1 I PE OI o A T o B INA KT J USER 1 A B I 1 SUPPLIED oa 1 l j E I o yl j C l fats pe CHR ok ah ee E ART 4 BEE 0 00 8 zi potis ye CAMAS Lic E Figure 20 Nonreversing with Shunt Trip Fault Isolation 22 1998 Square D All Rights Reserved VD0C32S301B Chapter 2 Wiring June 1998 Circuit Diagrams L1 L2 L3 lll w EP ADA S sw Fus FU4 Fus e FU1 FU2 k Kt Km FRERE LEES DE A I r REDE T 1 MAN ux co E we a 0 l l I A A DO l I Ai Bi Ci 111 312 513 C 500V 120V mm Een cies we dir de T T T 3 r MOTOR ER EE l l l TYPICAL THERMAL SW SE Wo I I I l POWER SOLID STATE BELOW o ROR RUN COMMAND I POLE OVERLOAD RELAY RELAY l l l i B l l l A2 B2 C2 om 4T2 6 T8 STOP RUN LI PL PERDE LU EN TS1 l l l Y T RCR L
9. tagged out before opening the controller door or performing parts replacement procedures Never assume the power is off Always check for voltage with a properly rated voltage sensing device Inspect the controller bonding and ground system and ensure that the controller is properly grounded per the applicable codes and recommendations in this instruction bulletin ATS46 controllers use some specialized components to achieve rated performance during operation Some of the components in the controller require special attention For example the SCRs require specific torque settings for proper operation When replacing parts follow the guidelines on page 2 and those listed throughout the book Be sure to install thermal grease when mounting components which use the heatsink for dissipating heat i e power semiconductor devices Always torque semiconductor components using the method described in the applicable parts replacement procedure If the controller is removed from its permanent mounting location while replacing parts ensure that it is properly secured in an upright position before re energizing During maintenance do not block impede or otherwise diminish cooling air flow over or through the controller When installing a new control module the controller may require programming if the factory default settings are not suitable for the specific application Avoid touching exposed conductors and component leads with skin or clothi
10. HAZARDOUS VOLTAGE Before checking thyristors Disconnect all power Place a DO NOT TURN ON label on the controller disconnect Lock disconnect in open position Electrical shock will result in death or serious injury To verify the damaged pole and determine how many poles should be replaced perform the following tests For D17 through C32 controllers the SCR modules can be directly accessed NOTE The ATS46C32N controllers use two SCRs per phase All other models use a dual pack SCR that requires one module per phase 1 With the equipment switched off isolate the starter by disconnecting the power terminals 2 Remove line power from controller Using a continuity meter check the thyristors in pairs Figure 49 illustrates this process phase by phase between terminals 1L1 2T1 3L2 4T2 5L3 6T3 If continuity is indicated at least one of the thyristors is short circuited Open SCR not failed Closed SCR failed Figure 49 Checking Thyristors 69 Chapter 6 Servicing the Controller Replacing the Control Module 70 VD0C32S301B June 1998 To remove the SCR module follow these steps 1 Disconnect all electrical connections to the SCR module Note the color and connection of each lead Remove only one SCR module at a time so that the other modules may be used as a reference when replacing the SCR module 2 Remove the power connections For D17 through C14 controllers Use a h
11. VD0C32S301B June 1998 Resetting the controller once the fault has cleared may not correct the condition that caused the fault to occur In addition there are failure modes of this controller which may require an external device to ensure power is removed from the motor Refer to Chapter 2 for proper installation guidelines CAUTION MOTOR OVERHEATING Failure of the controller solid state switches 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 motor locked rotor current Connect the Fault relay of the ALTISTART 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 The following guidelines provide general troubleshooting assistance based on the fault code displayed on the keypad If the controller is still inoperative after checking the motor and system status as recommended consult your local Square D sales office Fault Code P h F Possible Cause Mains supply failure greater than 500 ms when run command is present Motor current draw less than 10 of the nominal starter rating SCR failure Power factor greater than 95 lagging Corrective Action Verify that supply voltage is present on L1 L2
12. Open or loose power connections SCR failure not resettable via control logic Fault Code O L F Possible Cause Motor overload Excessive starting or stopping time or frequency Motor operating current incorrectly set Corrective Action nspect motor and driven equipment for problems including locked shaft mechanical overload e Check the dynamics of the load and driven machine for suitability with reduced voltage starting Check the duty cycle for the selected thermal overload class Check the I setting Fault Code h F Possible Cause Duty cycle above the thermal capabilities of the controller Ambient temperature too high Poor air circulation lack of ventilation Corrective Action Reduce duty cycle demand on controller Provide additional cooling around controller Reduce ambient temperature requirements Fault Code L r F Possible Cause Current greater than 500 of the motor FLA setting is detected for more than 200 ms during steady state operation Corrective Action Check motor for locked shaft Remove obstruction prior to restarting 59 Chapter 5 Fault Management Troubleshooting Faults Motor Underload Fault Max Start Time Exceeded External Fault Internal Serial Link Fault 60 VD0C32S301B June 1998 Fault Code LiL F Only applicable if ULL is programmed ULL is factory pre set to NO Possible Cause Load level below
13. 44 00 Figure 3 ATS46C17N to C32N Dimensions gt 2035 ES C Wa ka Pa G oh On 29 EZ ZH CE CI 1 094 ed D ES ET bab 24 WES Tm Detail D EEE Z 1 Typical 2 Places o I o Be dim D d a mm ojO i i i b c G weight in mm in mm in mm in mm in mm Ib kg ATS46C41N 15 8 401 37 4 950 13 9 353 13 2 335 31 5 800 123 56 ATS46C48N 15 8 401 37 4 950 13 9 353 13 2 335 31 5 800 137 62 ATS46C59N 15 8 401 37 4 950 13 9 353 13 2 335 31 5 800 137 62 ATS46C66N 15 8 401 37 4 950 13 9 353 13 2 335 31 5 800 137 62 Figure 4 ATS46C41N to C66N Dimensions 1998 Square D All Rights Reserved VD0C32S301B June 1998 1998 Square D All Rights Reserved See Chapter 1 Receiving and Installation Dimensions and Weights Detail E a EZ IEEE a S555 MT 09 6 0094 224 Detail E Typical 2 Places IBo o dim BLUR mm 9 n r y b H weight in mm in mm in mm in mm in mm Ib kg ATS46C79N 30 766 40 1012 14 353 27 5 700 31 5 800 247 112 ATS46M10N 30 766 40 1012 14 353 27 5 700 31 5 800 273 124 ATS46M12N 30 766 40 1012 14 353 27 5 700 31 5 800 273 124 Figure 5 ATS46C79N to M12N Dimensions Chapter 1 Receiving and Installation Handling the Controller VD0C32S301B
14. 200 ms This feature is only active when the shorting contactor is used to bypass the controller during steady state operation The current trip threshold may be adjusted from 50 to 300 of the nominal motor current for additional protection during steady state operation See Figure 34 If an overcurrent condition exists for more than 10 seconds an alarm is signalled through logic output LO2 Brief overcurrent conditions are allowed without nuisance tripping if the current decreases to a level 10 or more below the overcurrent limit within 10 seconds Short period overcurrent IL an obl 300 300 9 BO BO Hysteresis 77 Hysteresis 70 50 96 50 Alarm on LO2 D Reset Alarm 4 Alarm on LO2 t Figure 34 Current Trip Threshold e Continuous underload Set at 60 LE T BU In 100 To protect against underload conditions during steady state operation the underload limit may be adjusted from 20 to 100 of the motor load state See Figure 35 An underload fault is detected after 4 seconds of operation below the user defined level Brief underload conditions are allowed without nuisance tripping if the loading returns to a level 1096 or more above the underload limit within 4 seconds Short period underload IE rc T Set at 6096 Ih 100 Yo 4 60 60 Hysteresis
15. 212 11 82 300 15 21 6 90 ATS46D62N 9 45 240 13 00 0 6 58 167 8 35 212 11 82 300 15 21 6 90 ATS46D75N 9 45 240 13 40 340 9 61 244 8 35 212 11 82 300 23 59 10 70 ATS46D88N 9 45 240 13 40 340 9 61 244 8 35 212 11 82 300 23 59 10 70 ATS46C11N 9 45 240 15 37 390 9 61 244 8 35 212 13 79 350 26 24 11 90 ATS46C14N 9 45 240 17 34 440 9 61 244 8 35 212 15 76 400 35 28 16 00 Figure 2 ATS46D47N to C14N Dimensions Chapter 1 Receiving and Installation VDOC32S301B Dimensions and Weights June 1998 AMAT 0 A E E O a SSS ES eS O s ARMA 915 Detail C Detail C fi h Typical 2 Places G I f j a O i e G in L a N dim um 2 147 374 b c G weight in mm in mm in mm in mm in mm Ib kg ATS46C17N 14 34 364 26 99 685 10 60 269 13 36 339 19 70 500 97 02 44 00 ATS46C21N 14 34 364 26 99 685 10 60 269 13 36 339 19 70 500 97 02 44 00 ATS46C25N 14 34 364 26 99 685 10 60 269 13 36 339 19 70 500 97 02 44 00 ATS46C32N 14 34 364 26 99 685 10 60 269 13 36 339 19 70 500 97 02
16. 46D17N to 46C14N starters IP 00 ATS 46C17N to 46M12N starters Shock resistance Conforms to IEC 68 2 27 15g 11 ms ATS 46D17N to 46D38N starters Vibration resistance Conforms to IEC 68 2 6 NFC 20706 and BV1 Degree of protection Resistance to electrostatic discharges Conforms to IEC 1000 4 2 level 3 Immunity to radio electric interference Conforms to IEC 1000 4 3 level 3 Immunity to rapid electrical transients Conforms to IEC 1000 4 4 level 4 Operation 0 to 40 C without de rating between 40 C and 60 C de rate Ambient air temperature the ATS46 current by 1 2 for each C Storage 25 to 70 C Maximum relative humidity 93 without condensation or dripping water Maximum ambient pollution Degree 3 conforming to IEC 664 1000 m without de rating above this de rate the ATS46 current by 0 5 for each additional 100 m Maximum operating altitude Operating position Maximum vertical inclination 15 with respect to the normal mounting position IP 20 ATS 46D17N to 46C14N starters Degree of proiection IP 00 ATS 46C17N to 46M12N starters 1998 Square D All Rights Reserved VD0C32S301B June 1998 Table 3 Three phase supply voltage Chapter 1 Receiving and Installation Soft Start Application Electrical Characteristics 208 V 10 to 240 V 10 380 V 15 to 415 V 410 440 V 10 to 500 V 10 Frequency 50 Hz 2 5 Hz or 60 Hz 3 6 Hz s
17. Chapter 1 Receiving and Installation June 1998 Installation Precautions INSTALLATION PRECAUTIONS Follow these precautions when installing the ATS46 controller A DANGER HAZARDOUS VOLTAGE Read and understand this manual in its entirety before installing or operating ATS46 controllers Installation adjustment repair and maintenance of these controllers must be performed by qualified personnel Disconnect all power before servicing the controller DO NOT touch unshielded components or terminal strip screw connections with voltage present Install all covers before applying power or starting and stopping the controller User is responsible for conforming to all applicable code requirements with respect to grounding all equipment See Figures 1 5 on pages 5 7 for grounding points Many parts in the controller including printed wiring boards operate at line voltage DO NOT TOUCH Use only electrically insulated tools while making adjustments Before installing the controller Disconnect all power e Place a DO NOT TURN ON label on the controller disconnect Lock disconnect in open position Electrical shock will result in death or serious injury 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 A DANGER HAZARDOUS VOLTAGE The solid state switches of the ATS46 controller power circ
18. R1 N O contact of relay R1 OV Minimum switching capacity 100 mA 24 VDC Maximum operating voltage 400 V Rated operating current 0 5 A Inductive 240 VAC or 48 VDC R2A R2C 1998 Square D All Rights Reserved N O contact of relay R2 Control of shorting contactor 5A Resistive 240 VAC or 48 VDC Chapter 1 Receiving and Installation VD0C32S301B Soft Start Application June 1998 Table 5 Short Circuit Protection Type 1 With Power Fusing ree dei Altistart Model Max Amp Fault Current Max Amp Fault Current Fuse Class Rating Withstand Rating Rating Withstand Rating A rms sym A rms sym ATS46D17N RK5 30 65 000 30 5 000 ATS46D22N RK5 40 65 000 40 5 000 ATS46D32N RK5 50 65 000 50 5 000 ATS46D38N RK5 60 65 000 60 5 000 ATS46D47N RK5 75 65 000 80 5 000 ATS46D62N RK5 100 65 000 90 5 000 ATS46D75N RK5 125 65 000 100 10 000 ATS46D88N RK5 150 65 000 110 10 000 ATS46C11N RK5 200 65 000 150 10 000 ATS46C14N RK5 250 65 000 200 10 000 ATS46C17N RK5 300 65 000 225 18 000 ATS46C21N RK5 350 65 000 250 18 000 ATS46C25N RK5 450 65 000 350 18 000 ATS46C32N RK5 600 65 000 450 18 000 ATS46C41N L 650 65 000 600 18 000 ATS46C48N L 750 65 000 600 30 000 ATS46C59N L 1000 65 000 800 30 000 ATS46C66N L 1200 65 000 900 30 000 ATS46C79N L 1350 65 000 ATS46M10N L 1500 65 000 ATS46M12N E 1600 85 000 4 1998 Square D All Rights Reser
19. START AUTO DIRECTION 2 WIRE CONTROL W O AUTO 3 WIRE CONTROL 2 WIRE CONTROL W AUTO START MANUAL DIRECTION Te We PU VIAE SUN CE AE EA NERA O ce WB ad Ad DA ao ve Ena sa ETA ETER AA TER Ar EERS EE Dae dr Ada q OFF LI OFF OFF HAND AUTO FWD REV FWD REV ip HAND AUTO FWD REV B VI 1 1 l 1 gt lt gt lt Or o gt K o X t t A 6 F R l 1 1 A ES A j Lee EL l I i 0 gt 0 A IA EA e D 0 m f A USER SUPPLIED S r I R F 1 AX USER SUPPLIED D HH Figure 22 Reversing with Isolation Contactors j j j ji j j j USER SUPPLIED j j j j j j L 24 1998 Square D All Rights Reserved VD0C32S301B June 1998 Chapter 2 Wiring Circuit Diagrams Table 10 Description of Logic for Recommended Circuit Diagrams Item Name Description The isolation contactor logic closes KM1 upon a start command and opens KM1 after the stop is complete The RCR or KM1 RFR and RRR for reversing are timed contacts that must have a time delay greater than the deceleration ramp time or KM1A Isolation Contactor Forward the dynamic braking time When a coast stop is selected the time delay must be set for a time that will allow a complete decay of the motor residual voltage The isolation contactor will open immediately upon a fault The pilot r
20. To re start the motor the fault condition must be cleared and the controller must be reset The method used to reset the controller depends on the type of fault detected and if automatic re start is selected 1998 Square D All Rights Reserved VD0C32S301B June 1998 Fault Definitions Chapter 5 Fault Management Resetting the Controller The ATS46 controller continuously monitors the motor and starter performance If a fault is detected the controller will interrupt motor operation and switch to a freewheel stop After the fault has cleared the steps required to restart the motor depend on the type of fault that was detected The following is a guide for restarting following a fault condition Cycle Control Power Cycling control power resets the controller following any fault condition and is required for non resettable faults A new or maintained run command will restart the motor after control power is recycled if the fault has cleared Manual Restart The controller may be restarted by issuing a new run command after any resettable fault once the fault has cleared Auto Restart If selected the controller will restart automatically only if a maintained run command is preset when using two wire control An automatic restart will only occur after specific faults have cleared Following a Type 1 fault the controller will restart once the fault has cleared Following a Type 2 fault the controller will attempt to restart the moto
21. all voltage is removed Level 1 or 2 from the motor following a STOP command The motor coasts to a stop with the deceleration time dictated by the inertia and resistive torque of the driven load If deceleration ramping d is selected the user may dEc five ui ramp A 1 to 60 seconds 10 adjust the ramp time and voltage at which the ramp ends Level 1 or 2 dE c is used to adjust the time to change from measured torque to zero torque If deceleration ramping 4 is selected the torque level at Threshold for change which the Mob pd AMP aS wl be IRE Once d torque reaches the threshold value the controller changes to Ede one arend ol A d j an nu ed freewheel mode and the motor coasts to a stop If the torque Level 1 or 2 is below the threshold setting when a stop command is given controlled deceleration is not activated and the controller changes to freewheel stop Braking torque level If braking b is selected adjusts the braking level used bre Level 1 or 2 A 0 to 100 50 during InTele braking Note that the duration of the braking application is dependent on the motor loading If torque is too low on starting due to dry friction stiff bSE Voltage boost 6 50 to 100 of the supply a F F mechanism or high inertia the boost function provides Level 2 only voltage increased torque to initiate motor shaft rotation Voltage is applied for 5 mains cycles during boost Adjusts the initial torque upon energization The initia
22. applying a soft start successfully is matching the load to the motor capability while starting with reduced voltage applied The ALTISTART 46 is factory preset to start the motor for which the controller is rated for standard duty applications A switch is located behind the removable keypad that can be toggled from standard duty to heavy duty application presets For standard duty applications the ALTISTART controller is preset for Class 10 overload protection a 300 current limit and 10 second acceleration ramp Typical standard duty applications include most fans and centrifugal pumps Other standard duty applications include machines such as screw type compressors or conveyors that are started with light or no load At the standard duty default settings 10 starts per hour may be achieved for a maximum of 23 seconds per start without tripping The standard duty horsepower rating of the controller is listed on the device nameplate Applications requiring long start times high starting torque or frequent starting and stopping may require de rating of the controller or the use of a shorting contactor to bypass the controller once the motor is up to speed For heavy duty applications the ALTISTART controller is preset for Class 20 overload protection a 350 current limit and 15 second acceleration ramp Heavy duty applications include high inertia loads or other loads requiring long acceleration times Some examples of heavy duty applications i
23. automatically disconnecting the motor from the line supply This external disconnect provides protection for the motor driven machinery and operating personnel The ATS46 controller provides several inputs and outputs that can be adapted to a variety of functions The controller is preset at the factory to meet the requirements of most applications The functions of the inputs outputs and optional configurations are described below One normally opened and one normally closed contact is supplied for indication of fault or control of an isolation contactor In the default mode R1 contacts change state if a fault is detected The contacts are in their normal state upon application of control power Once the self diagnostic check is completed if no fault is found the fault relay energizes The fault contacts will change to their de energized state if a fault condition is detected or if control power is lost If configured for control of an isolation contactor the R1 contacts stay in their normal state until a run command is initiated The R1 contacts then stay energized until a fault condition is detected or until deceleration is complete This allows the user to coordinate an isolation contactor to disconnect the motor from the line under a fault condition or when the motor is not in use A normally open relay is provided to allow for easy integration of a shorting contactor The end of start up relay closes once the motor has reached full s
24. configured by the user to provide detection of a fault only or control of an isolation contactor A normally open and normally closed contact are provided to signal external devices When in the factory default configuration the R1 relay will energize following a successful self diagnostic test and remain energized until a fault condition is detected The 81 relay is in the de energized state when control power is not applied and when a fault is detected If configured for control of an isolation contactor the R1 relays stay in the de energized state until a start command is issued Following a start command the R1 relays remain energized until deceleration is complete or until a fault is detected If controlled deceleration is not selected the R1 relays change state following a stop command This provides automatic interruption of the line voltage following a fault and when the motor is not in use If a fault occurs during the operation of the ALTISTART controller a fault code is displayed on the keypad indicating the starter status The last five faults that have occurred are stored in controller memory To view the fault memory buffer use the PC or PLC option To view the controller settings while a fault code is displayed press the DATA push button until the programming menu is displayed A red LED on the front of the controller also indicates a fault condition Fault conditions are broken into three categories internal phase and thermal
25. controller Anycircuit 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 ATS46 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 motor power should a failure occur auxiliary isolation on the line side of the controller is required The isolation device must be capable of operation via command from the Fault relay of the controller An isolation device consisting of either a circuit breaker incorporating a shunt trip coil or an electromagnetic contactor can be used to open the controller power circuit in the event of a controller fault Refer to Figures 20 through Figures 22 on pages 22 through 24 for typical circuit diagrams that display the logic controlling the isolation device via the fault relay 10 1998 Square D All Rights Reserved VD0C32S301B Chapter 1 Receiving and Installation June 1998 Installation Precautions A CAUTION MOTOR OVERHEATING Failure of the solid state switches on the ATS46 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
26. externally The various thermal overload protection classes are defined to meet the standards of IEC 947 4 2 for starting from both cold and hot states Starting from a cold state is defined as the stabilized motor thermal state when the motor is off Figure 31 shows the approximate trip times for starting from a cold state 1998 Square D All Rights Reserved VD0C32S301B Chapter 3 Application and Protection June 1998 Motor Protection and Diagnostics 1000 100 Class 30 Class 25 ass 20 C Class 15 C ass 10 O ass 10A 1 Class 2 0 5 8 00 7 50 7 00 6 50 6 00 5 50 5 00 4 50 400 3 50 3 00 250 200 15 142 Figure 31 Cold Start Curves Starting from a hot state is defined as the stabilized motor thermal state when the motor has been running at full load capacity Figure 32 on page 36 shows the approximate trip times for starting from a hot state 1998 Square D All Rights Reserved 35 Chapter 3 Application and Protection VD0C32S301B Motor Protection and Diagnostics June 1998 1000 100 Class 30 Class 25 Class 20 Class 15 Class 10 Class 10A 1 Figure 32 Hot Start C
27. operation of the controller in an enclosure with a maximum internal temperature of 140 F 60 C De rate the controller current by 1 2 per C for temperatures above 40 C or where applicable use a shorting contactor duty cycle not to exceed 2 starts per hour Do not use insulated or non metallic enclosures as they have poor thermal conduction Locate the fan and ensure that ambient temperature around the controller is within the specifications To reduce temperature rise within the enclosure use a shorting contactor 47 A units and higher Use a heat exchanger when necessary to keep internal temperatures within specification PESE ATS Figure 8 Ventilation for Dust and Damp proof Enclosure When mounting the ATS46 controller 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 within the enclosure Table 6 lists the steady state power dissipation for the ATS46 controller operating at rated current Table 6 Power Dissipated by Controllers at Rated Current Controller Reference Power inW Controller Reference Power in W ATS46D17N 72 ATS46C21N 670 ATS46D22N 79 ATS46C25N 795 ATS46D32N 109 ATS46C32N 973 ATS46D38N 121 ATS46C41N 1404 ATS46D47N 158 ATS46C48N 1452 ATS46D62N 206 ATS46C59N 1800 ATS46D75N 255 ATS46C66N 2025 ATS46D88N 296 A
28. side panels down 6 Remove the filter card 7 Use a magnetic screwdriver to reinsert screws To reinstall the filter card reverse steps 1 to 5 Retighten the housing screws and power connections To replace the filter card on C17 through C32 controllers follow these steps 1 Remove electrical connections for the card to be replaced 2 Using a Torx screwdriver remove the mounting screw 3 Remove the filter card 4 To reinstall a new filter card reverse steps 1 through 3 To remove the current measurement board 1 For D47 through C32 controllers disconnect jumpers J13 J14 and J15 from the current measurement board See Figure 50 on page 70 2 Using a Torx screwdriver loosen and remove the holding screws on the current measurement board 3 On D17 through D38 controllers the current transformers are mounted directly on the current measurement board To remove the board the three bus wires from the SCRs have to be disconnected and pulled out from the current transformer NOTE To remove the bus wire from the current transformer it may be necessary to remove the heat shrink from the terminal of the bus wire Replace heat shrink upon re installation 4 Remove measurement board from power section note connections for reassembly On ATS46D75 through C32N controllers there are two thermal switches One controls the operation of the cooling fan and the other is an alarm for controller thermal protection The output of the he
29. the current transformers scales it and provides the control module with motor current information for the control algorithms For controllers with ratings of 410 A or higher the current measurement board includes the gate drivers that higher rated SCRs require If the current measurement board is damaged acceleration or deceleration will not occur properly To verify whether the current measurement board is working properly compare the current display on the keypad to actual measured current Typical causes of measurement board damage include exposure to a short circuit excessive current flow or improper shorting contactor sequencing Replace the measurement board when replacing SCRs that are damaged by short circuit or lightning strike Measurement Measurement L1 L2 L3 L3 L3 L3 A2 B2 C2 C2 C2 C2 TI T2 T3 T3 T3 T3 AST46C41 C66N AST46C79 M12N Figure 57 Power Pole Configuration for C41 to M12 Controllers To remove the current measurement board follow these steps 1 Disconnect the plugs from the current measurement board See Figure 58 2 Using a Torx screwdriver loosen and remove the holding screws from the current measurement board 3 Carefully remove the measurement board from the power section Note the location of the removed connections To Firing Interface Board J4 J6 J8 only on C41 C66 controllers J4 J6 J8 a
30. the set ULL level Damage to drive train broken belts shafts etc Pump running dry or with no flow Corrective Action Check the application for changes that may cause performance outside acceptable limits Change in process loading or operation Mechanical system inspection Incident in pump hydraulic circuit Fault Code 5 F Only applicable if tLS is programmed tLS is factory pre set to NO Possible Cause Start time exceeds tLS maximum start time setting Change in process loading or operation Corrective Action Check the application for changes that may cause performance outside acceptable limits Mechanism wear Mechanical incident Fault Code Only applicable if LI is programmed to detect external fault LIE LI is factory pre set to NO Possible Cause External fault detected and signaled to the logic input Corrective Action Check external fault detection mechanism Fault Code 51 F Possible Cause Bad connection of the keypad or serial link option module Corrective Action Check option module connection Replace option module 1998 Square D All Rights Reserved VD0C32S301B June 1998 Overcurrent Fault Internal Failure Fault Phase Inversion Fault 1998 Square D All Rights Reserved Chapter 5 Fault Management Troubleshooting Faults Fault Code c F Possible Cause High impedance short circuit at the o
31. through C32 controllers follow these steps 1 Remove the fan cover by removing the two cover screws 2 Remove the six screws from the fan mounting plate 3 Disconnect the fan power supply wires from the control power transformer White and from the thermal switch Red See Figure 51 4 Remove the fan assembly 5 To reinstall the replacement fan reverse steps 1 through 4 Use caution when installing the fan to prevent damage to the wires White Red Red White Figure 51 Fan Mounting Plate The control power transformer CPT provides the power to the control module and fan if supplied To replace the CPT the user must have access to the fan connections Refer to Thermal Switch and Fan Replacement on page 71 to service the fan assembly To replace the CPT follow these steps 1 Disconnect the four colored transformer supply wires from the terminal block beneath the control power connections See Figure 57 on page 76 2 For D72 through C32 controllers disconnect the two wires that supply the fan power For C17 through C32 controllers pull the fan power wires through the fan and controller housing one at a time 3 Remove the four transformer mounting screws attaching the transformer to the power section base 4 Remove the CPT 5 To install a replacement CPT reverse steps 1 through 4 See Figure 57 Note the proper connections we Green Bue Res From CPT Figure 52 Control Po
32. to achieve published short circuit withstand ratings Do not exceed the maximum OCPD ratings shown in Appendix A Do not connect the controller to a power feeder whose short circuit capacity exceeds the controller short circuit withstand rating shown in Appendix A 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 ATS46 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 ATS46 controller Failure to follow this instruction can result in injury or equipment damage The ATS46 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 A CAUTION EQUIPMENT DAMAGE HAZARD Do not perform high potential dielectric tests on circuits while the circuits are connected to the ATS46
33. variable torque loads A torque ramp provides a higher level of control than is available with typical voltage ramping or current limiting soft starters As shown in the diagrams below torque ramping compared to a current limited start can provide a more linear speed ramp reduces the surge of acceleration typical for most soft starts and minimizes the motor temperature rise by reducing the amount of current drawn during acceleration Speed Current 4 4 Torque Ramp Current Limit Torque Ramp Time gt I j l j l j j L Figure 25 Torque Ramp vs Current Limit Starting The torque ramp time or the time to increase from zero torque to the nominal torque of the motor may be adjusted from 1 to 60 seconds The initial torque applied is preset for 10 of the motor nominal torque but may be adjusted from 0 to 100 for maximum flexibility and adaptability for varying loads 31 Chapter 3 Application and Protection Modes of Stopping Torque Limit Current Limit Voltage Boost MODES OF STOPPING Deceleration Ramp 32 VD0C32S301B June 1998 As Figure 26 illustrates the maximum motor torque may be limited to between 10 and 100 of the motor nominal torque This feature is primarily used to limit acceleration of high inertia or constant torque applications If used the torque limit combines with the acceleration ramp and initial torque settings to provide a highly customized acceleration to
34. 2 LIST OF TOOLS AND INSTRUMENTS 63 STANDARDS s r Gor EE SR REI Rt UE UR ow EROR UR 63 PARTS REPLACEMENT ret enc eae Py WERE AWA oet 64 CONTROL MODULE REPLACEMENT 65 POWER SECTIONREPAIR 66 ATS46D17 to C32 Controllers 66 SCR Replacement 67 Filter Card Replacement 69 Thermal Switch and Fan Replacement 69 Control Power Transformer CPT Replacement 70 POWER SECTION REPAIR 2e 71 ATS46C41N to M12 Controllers 71 SCR Power Pole Assembly 71 Firing Interface Board Replacement 72 Current Measurement Board Replacement 74 Thermal Switch Replacement 75 Fan Replacement 4 4 2al RR L Waa Ne OY d a EE akla k A ERE ERR INR ERE 75 Control Power Transformer Replacement 75 1998 Square D All Rights Reserved Bulletin No VD0C32S301B June 1998 1998 Square D All Rights Reserved ALTISTART 46 Soft Start Controller Contents ALTISTART 46 Soft Start Controller Bulletin No VD0C32S301B Content
35. 20 Table 20 on page 65 lists the factory preset for the motor nominal current h and corresponding motor combinations for standard duty and heavy duty presets If the motor full load amp rating is not within 95 and 105 of the ATS46 controller factory preset value or if motor has a 1 0 service factor adjust the controller for optimal motor protection and performance Tables 16 and 17 provide the Level 1 2 and 3 factory presets for the other parameters available NOTE If purchasing a Class 8636 8638 or 8639 Enclosed ALTISTART refer to the supplemental instruction bulletin provided Modifications have been made to the factory settings listed above for some enclosed products to more closely match the motor full load amp ratings at the specified motor voltage In addition if an input contactor is provided the H1 relay has been re set for isolation contactor control A keypad is provided to allow digital set up of the controller and real time indication of motor performance The keypad has three seven segment display characters one program LED and four pushbuttons for programming the controller as shown in Figure 37 The keypad may be removed after loosening the holding screw and can be removed while the controller is switched on The keypad does not have to be in place in order to operate the controller 1998 Square D All Rights Reserved VD0C32S301B June 1998 Chapter 4 Controller Setup and Operation Proga
36. 3 Control Parameters oers kp er ur WA 43 Parameter Flowcharts iia IEEE RERO TRI a 45 Setting the Motor Current 51 Setting the Current Limit 51 Advanced Acceleration Ramp Adjustments 51 41 Chapter 4 Controller Setup and Operation Factory Presets FACTORY PRESETS USING THE KEYPAD 42 VD0C32S301B June 1998 The ALTISTART 46 ATS46 controller is factory preset which for many applications allows operation without requiring adjustment As shown in Figure 36 a switch is located behind the removable display module that can be toggled from standard duty to heavy duty application presets r f Ez o o o 9 1 Standard Duty 2 Heavy Duty Figure 36 Factory Preset Selector Switch The ATS46 controller is factory preset to standard duty operation To switch the factory presets to heavy duty applications remove the control module and change the selector switch to position 2 as shown in Figure 36 inset For the change to take effect control power must be cycled after adjusting the selector switch The following factory presets change when adjusting the selector switch from position 1 to position 2 Parameter Standard Duty Preset Heavy Duty Preset Acceleration Ramp Ac 10 seconds 15 seconds Current Limit lt 300 350 Overload Protection thp Class 10 Class
37. 4s 20 Fault ULF Figure 35 Motor Load Limit Examples 1998 Square D All Rights Reserved mt 10 20 Hysteresis 70 No Fault Fault c r 4 ES ony 37 Chapter 3 Application and Protection Controller 1 0 Configuration Protection from Line Faults CONTROLLER VO CONFIGURATION Faults lso Contactor Control Relays End of Start up Relay Logic Output 38 VD0C32S301B June 1998 The ATS46 controller provides protection from line faults while allowing for continued operation when supplied with typical industrial power that may contain minor disturbances The ATS46 controller interrupts motor operation if the following fault conditions are detected Mains supply failure greater than 500 ms Loss of motor phase or shorting contactor connection Supply frequency outside limits upon initialization For 60 Hz operation the supply frequency must be between 56 4 and 63 6 Hz For 50 Hz operation the supply frequency must be between 47 and 52 5 Hz Phase reversal may be selected to prevent operation if the supply phase rotation does not correspond to the specified rotation direction The ATS46 controller also trips on overcurrent due to a short circuit at the controller a shorted SCR or a shorting contactor malfunction Although the controller may detect these faults the user must install an external means of
38. CONTROL MODULE REPLACEMENT 1998 Square D All Rights Reserved Chapter 6 Servicing the Controller Replacing the Control Module CAUTION EQUIPMENT DAMAGE ALTISTART 46 controllers use metric fasteners Do not substitute SAE or alternate fasteners Failure to follow this instruction can result in equipment damage ATS46 controllers use metric fasteners and require the use of metric driver tools Do not substitute SAE or any alternate fastener Substitution may result in damage to threaded inserts breakage of components and subassemblies overheated electrical connections due to improper torque levels and general structural failure All procedures in this section must be performed with power removed from the controller To gain access to the power section or for replacement on all ATS46 models remove the control module To remove the control module follow these steps 1 Using a flat blade or Torx screw driver remove the four screws from the front of the control module 2 Using aconnector extractor disconnect the nine electrical connectors from the back of the module While the connectors and module are labeled note the label and location of each connector Figure 45 shows a diagram of the module and its connector labels blue urple J31J32 J21J22 Ji 112 4 wine blask red red J 1 J 2 DU Ong Keypad provided Typical Connection separately to SCRs il Bac
39. F150G6 LC1 F150G6 LA9 FF970 LC1 F150G6 RK5 200 6R200A3BE KHL36000M LC1 F185G6 LC1 F185G6 LA9 FG970 LC1 F185G6 RK5 250 6R400A3B KHL36000M LC1 F265G7 LC1 F265G7 LA9 FJ970 LC1 F265G7 RK5 350 6R400A3B LHL36000M LC1 F330G7 LC1 F330G7 LA9 FJ970 LC1 F330G7 RK5 400 6R400A3B LHL36000M LC1 F400F7 LC1 F400F7 LA9 FJ970 LC1 F400F7 RK5 500 6R600A3B LHL36000M LC1 F400F7 LC1 F400F7 LA9 FJ970 LC1 F400F7 RK5 600 6R600A3B MHL360006M LC1 F500F7 LC1 F500F7 LA9 FJ970 LC1 F500F7 L 650 5 MHL360008M LC1 F500F7 LC1 F500F7 LA9 FJ970 LC1 F500F7 L 800 5 MHL360008M LC1 F630F7 LC1 F630F7 LA9 FL970 LC1 F630F7 L 1000 5 MHL36000M LC1 F630F7 LC1 F630F7 LA9 FL970 LC1 F630F7 L 1200 5 MHL36000M LC1 F780F7 LC1 F780F7 LA9 FX970 LC1 F780F7 L 1600 5 NCL3600012M Notes continued 7 Power terminals are not included with LC1 F or LC1 B contactors Refer to the latest editions of the Square D product catalogs for additional ordering information 8 Reversing contactors for C15 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 the Square D product catalogs for power connector link and terminal kits Reversing contactor interlock units used for the C82 through M12 controllers are designed for vertical interlocking of the individual contactors Horizontally interlocked contac
40. Fault Management June 1998 CHAPTER 5 FAULT INTRODUCTION 54 MANAGEMENT Fault Relay Setup i see AS SE GE ie e EU ee ERE 54 Fault Display x ers het hte d a ee wt dr 54 RESETTING THE CONTROLLER 54 Fa lt DefihiliOl l8 2z kk GER EE Ee E al ES ns nA Ed al 55 TROUBLESHOOTING FAULTS 56 Ad Vi rete Rote eee UD EE See AA ute See he 56 Frequency Fault ua Ayn de ia A e 56 Supply Fault with Run Command Present 57 Motor Thermal Fault 57 Starter Thermal Fault ad 57 Locked Rotor Fault ss ss a xA ee ews die Go ean 57 Motor Underload Fault 58 Max Starting Time Exceeded 58 External Fault i sou eee ee ORE EYAWG ne nr 58 Internal Serial Link Fault 58 Overc rrent Fault 2224 ci a a eds ah eee RI 59 Internal Failure Faul ui ideasi nalal n k kal k 4 an nk laya y kla l 59 Phase InversionFault 59 1998 Square D All Rights Reserved 55 Chapter 5 Fault Management Introduction INTRODUCTION Fault Relay Set
41. June 1998 Do not remove the ALTISTART 46 ATS46 controller from the carton until it is at the final HANDLING THE CONTROLLER SERIAL AND MODEL NUMBERS 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 rings on top of the controller as shown in Figure 6 Ina horizontal position with the back of the controller resting on a pallet NOTE Do not rest unit directly on bus bar connectors A WARNING HANDLING AND LIFTING HAZARD Keep area below any equipment being lifted clear of all personnel and property Use lifting method shown in left hand portion of Figure 6 Failure to follow this instruction can result in death or serious injury LIFTING FORCE Figure 6 Hoisting the ATS46 Controller The serial and model numbers of the ATS46 controller appear on the bar code sticker located on the front right side of the component Serial Number 6W9717001001 03 833085222A05 TT ATS46D47N Record the serial number below This number will assist us in helping you in the future Serial Number 6W Model Number 1998 Square D All Rights Reserved VD0C32S301B
42. L3 terminals If an isolation contactor is used it must close within 200 ms of a run command Check for open phases including Blown fuses Open or loose power connections SCR failure not resettable via control logic If the fault is detected after completion of the acceleration ramp ensure that the proper connection of the shorting contactor if used The output of the shorting contactor must be connected to terminals A2 B2 C2 and must close within 200 msec after the motor is up to speed Motor current draw must be more than 10 of the controller rating while running without a shorting contactor Fault Code F r F Possible Cause e Mains supply frequency outside acceptable limits Corrective Action Check that the frequency is between 60 Hz 3 6 Hz 56 4 Hz to 63 6 Hz 50 Hz 2 5 Hz 47 5 Hz to 52 5 Hz 1998 Square D All Rights Reserved VD0C32S301B June 1998 Supply Fault with Run Command Present Motor Thermal Fault Starter Thermal Fault Locked Rotor Fault 1998 Square D All Rights Reserved Chapter 5 Fault Management Troubleshooting Faults Fault Code U5 F Possible Cause Voltage is not present at L1 L2 L3 terminals when a run command is present Corrective Action Verify that supply voltage is present on L1 L2 L3 terminals If an isolation contactor is used it must close within 200 ms of a run command Check for open phases including Blown fuses
43. O Bed O 1L1 O 32 O 5L3 O 211 55i 4T2 6T3 14mm Figure 11 Bus Bar Power Connections ATS46C17N to C32N 1998 Square D All Rights Reserved Chapter 2 Wiring Wiring Bus Connection Dimensions inches 18 4 6 4 6 4 8 E s ee Figure 12 Bus Power Connection Dimensions ATS46C41N to C66N VD0C32S301B June 1998 ND C L1 A2 L2 B2 Ti i3 C2 T2 7 T3 TYPICAL 55in 14mm 48 7 9 11 5 gt Figure 13 Bus Connection Dimensions ATS46C79N to M12N 1998 Square D All Rights Reserved VD0C32S301B June 1998 CONTROL CONNECTIONS 1998 Square D All Rights Reserved Chapter 2 Wiring 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 only Ensure that the coils of all relays and solenoids connected to the output contacts of th
44. OF STARTING cel eb Da ee RU am W 31 Acceleration Ramp z isses epee bs a ia pi ERG CERES 31 Torgue LimiIt EER REM taa ane Dune en Gan ka dans d E 32 Gurrent Limit yx A3 A fe de ae E Re idee 32 Voltage Boost ER este IER IEEE SES 32 MODES OF SIOPPING z coca eee Shes DA i4 32 Deceleration Ramp kk kk kk kk ete eee hn 32 InTele Braking gt 4 EE ge ode ened eb end BE PR ed IMS ee lined Stee 33 MOTOR PROTECTION AND DIAGNOSTICS 33 Thermal Overload Protection 33 Excessive Cycling Prevention 36 Stall and Steady State Protection 37 Protection from Line Faults 38 CONTROLLER I O CONFIGURATION 38 Faults ISO Contactor Control Relays 38 End of Start Up Relay 38 Logic Output 2 2 A l eg A Hier dH ER 4 38 Analog Output ire si Wa W nn ad y ee WE MD e iu RE 39 Ui A med OE S 39 DISPLAY OF MOTOR VALUES 39 29 Chapter 3 Application and Protection SOFT START APPLICATION Standard Duty Applications Heavy Duty Applications Reduced Torque VD0C32S301B June 1998 The key to
45. ROL W AUTO 2 WIRE CONTROL W O AUTO 3 WIRE CONTROL I OFF Cr 3 L TP ar WE ji gt ge A ae D 1 User supplied j HAND AUTO STOP START i B i l l n qe oi j o o o1 A o aloso o o B I i l i SUPPLIED im M e J L l ji l IT i j j j C Figure 21 1998 Square D All Rights Reserved Nonreversing with Isolation Contactor 23 Chapter 2 Wiring VD0C32S301B Circuit Diagrams June 1998 LL Lo m Dy ci PEN 60 EL FYN 120V dg a CE c EEE d MOTOR THERMAL SW 8 RRR RUN FWD 9 oe T LA RELAY SEE C TE I BELOW 0 REB TS1 l l D RFR l I l l AT Bi Ci 1 1 3 2 5 L3 c 500V i oe ad l L 1 l se al E I KM3 j KM3 KM3 a J 1 RRR T8 1 TT r ATS FAULT en lt 44 8 CN FAULT O N l I l TYPICAL FR I I I l POWER SOLID STATE ee oe i i I POLE OVERLOAD RELAY TS1 I l I A2 B2 c2 271 4 12 6 13 STOP RUN LI PL l I l Y T T S i ara 7 M GA FORWARD 1 1 3 AP 1 CONTACTOR l Laas l l bue aes eR ee RRR KM1 RRR KM1 FN REVERSING KM2 CONTACTOR RFR KM2 NC
46. TS46C79N 2680 ATS46C11N 342 ATS46M10N 3010 ATS46C14N 411 ATS46M12N 3640 ATS46C17N 550 Part number VW3G46103 includes all hardware necessary to mount the display module in a remote location up to three meters from the ATS46 controller When mounted externally the protection index of the display module is IP65 suitable for use on a TYPE 12 enclosure 13 Chapter 1 Receiving and Installation Remote Mounting Keypad 14 VD0C32S301B June 1998 1998 Square D All Rights Reserved VD0C32S301B Chapter 2 Wiring June 1998 CHAPTER 2 WIRING lise 16 General Wiring Practices 16 Adaptation to Line Input 16 Power Connections 16 Bus Connection 14 53 A esl bpd pup bg AN o 4 0 18 CONTROL CONNECTIONS 19 logie Input IE ee OR gg mm 21 Logic Outputs seed BEE EER eet eee RE UE IUE 21 Analog Outp t inh pL IRR eee Eat ocd oly a dass RIS 21 REMOTE MOUNTINGKEYPAD 22 CONTROL CIRCUIT DIAGRAMS 22 RECOMMENDED COMPONENT LIST 26 1998 Square D All Rights Reserved 15 Chapter 2 Wiring Wiring WIRING General Wiring Practices Adaptation to Line Input Power Connections 16 VD0C32S301B June 1998 Good wiring practice requires t
47. Torque as a Function of Applied Voltage 30 O 1998 Square D All Rights Reserved VD0C32S301B June 1998 MODES OF STARTING Acceleration Ramp 1998 Square D All Rights Reserved Chapter 3 Application and Protection Modes of Starting A soft start progressively increases voltage to the motor By ramping the voltage the ATS46 controller limits the amount of current the motor can draw during starting to a user defined setting Figure 24 shows the speed torque characteristics of a motor as a function of starting current The ATS46 controller provides optimal acceleration by ramping the acceleration torque within the envelope of curve Ty Current J Toad ld Starting current at full voltage locked rotor amps aard a ui la Current limit during Soft Start 0 Rated 0 025 05 075 Speed Figure 24 Torque as a Function of Starting Current The ATS46 controller is factory preset for simple out of the box operation in many applications The factory preset provides a 10 second acceleration ramp with 30096 of the factory preset nominal current TCS Torque Control System ramp is the most widely used acceleration ramp It is ideal for applications that require a smooth stepless start The ATS46 controller uses patented technology to calculate the motor torque continuously Basing the TCS ramp on the motor torque provides constant acceleration torque ideally suited for most fans centrifugal pumps or other
48. VD0C32S301B June 1998 Instruction Bulletin Raleigh NC USA ALTISTART 46 Soft Start Controller User s Manual DI SOUARE D DANGER HAZARDOUS VOLTAGE Read and understand this manual in its entirety before installing or operating ALTISTART 46 ATS46 controllers Installation adjustment repair and maintenance of these controllers must be performed by qualified personnel Disconnect all power before servicing controller DO NOT touch unshielded components or terminal strip screw connections with voltage present Install all covers before applying power or starting and stopping the controller User is responsible for conforming to all applicable code requirements with respect to grounding all equipment See Figures 1 5 on pages 5 7 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 Before installing controller Disconnect all power Place a DO NOT TURN ON label on the controller disconnect Lock disconnect in open position Electrical shock will result in death or serious injury 1998 Square D Company All rights reserved This document may not be copied in whole or in part or transferred to any other media without the written permission of Square D ALTISTART and TCS are registered trademarks of Telemecanique S A or its successor in interest Schneide
49. aking During steady state operation the u n display is steady If a fault is incurred during diagnostics or controller operation the applicable fault code is displayed in place of the controller status display 1998 Square D All Rights Reserved 49 Chapter 4 Controller Setup and Operation Adjusting Controller Settings Table 16 Level 1 and 2 Parameters VD0C32S301B June 1998 Parameter Type Display Range Preset Description The nominal motor current is factory set according to the See controller rating and position of the switch beneath the keypad j Nominal motor current C 50 to 130 of the controller Table 20 If the factory setting is not between 95 and 105 of the motor a Level 1 or 2 rated current on FLA rating adjust the 1 to obtain optimal performance and page 65 thermal protection See Setting the Motor Current on page 52 ILE Current Limit A 150 to 700 joo Sets the maximum current drawn during acceleration See Level 1 or 2 max 500 le Setting the Current Limit on page 53 Acceleration torque Adjusts the acceleration torque ramp Adjusting the Ac c Hec ramp A 1 to 60 seconds IU setting changes the slope of the torque reference providing a Level 1 or 2 more or less gradual start Selects the stopping control method Selecting F d or b indicates freewheel deceleration ramp GEY Stop type C npe edo Sk F or braking In freewheel mode F
50. ated Standard Duty Applications Heavy Duty Applications Current Motor Power Rating Motor Power Rating laL 208V 230V 460V 208V 230V 460V ATS46D17N 17 3 5 10 2 3 7 5 ATS46D22N 22 5 7 5 15 3 5 10 ATS46D32N 32 7 5 10 20 5 7 5 15 ATS46D38N 38 10 25 7 5 10 20 ATS46D47N 47 15 30 10 25 ATS46D62N 62 15 20 40 15 30 ATS46D75N 75 20 25 50 15 20 40 ATS46D88N 88 25 30 60 20 25 50 ATS46C11N 110 30 40 75 25 30 60 ATS46C14N 145 40 50 100 30 40 75 ATS46C17N 176 50 60 125 40 50 100 ATS46C21N 210 60 75 150 50 60 125 ATS46C25N 257 75 100 200 60 75 150 ATS46C32N 320 100 125 250 75 100 200 ATS46C41N 410 125 150 300 100 125 250 ATS46C48N 480 150 350 125 150 300 ATS46C59N 590 200 400 150 350 ATS46C66N 660 200 250 500 200 400 ATS46C79N 790 250 300 600 200 250 500 ATS46M10N 1000 350 400 800 250 300 600 GROUPE SCHNEIDER M Merlin Gerin MW Square D M Telemecanique VDOC32S301B June 1998 Printed in USA 1998 Square D All Rights Reserved
51. atsink thermal switch is fed to the current measurement board The output of the fan control is in series with the fan and control power transformer The cooling fans cycle on when the temperature of the heatsink exceeds 50 C If the cooling fan does not turn on and the temperature exceeds 50 C the thermal switch the fan or both may need to be replaced The fans operate on 230 VAC single phase power Use an external power supply if desired to test fan operation To replace a thermal switch follow these steps 1 Disconnect the two electrical connections from the output of the switch 2 Using a Torx or flat blade screwdriver remove the two holding screws It may be necessary to remove some of the SCR power connections to access the thermal switch 3 Replace the thermal switch with the appropriate rated switch The fan thermal switch should be rated for 50 C whereas the heatsink switch is rated for 95 C or 105 C depending on the controller size 71 Chapter 6 Servicing the Controller Replacing the Control Module Control Power Transformer CPT Replacement 72 VD0C32S301B June 1998 To replace the fan on D75 through C14 controllers follow these steps 1 Turn the unit with the heatsink facing up i e access the fan from the back of the unit 2 Remove the two electrical connections 3 Remove the two holding screws 4 To install the replacement fan reverse steps 1 through 3 To replace the fan on C17
52. ault and configuration of the R1 relay Refer to Chapter 4 for Fault relay status if using automatic restart R1B R1D Relay N C Fault R1A R1C Output N O Fault Relay contact will close when the controller has completed the acceleration ramp and the current draw of the motor is less than 130 of the motor FLA or the setting of Ip setting Contact is Relay N O End of coordinated with the thyristors on a stop command or fault Output Start up condition This relay is typically used to control a contactor that bypasses the controller after start up to ease thermal management of the installation If a shorting contactor is not used the status of this relay may be indeterminate following a phase failure fault R2A R2C Refer to Table 3 on page 3 for electrical characteristics End Startup Off Relay R2A R2C 500 ms max 500 ms max On Shorting Off Contactor KM3 Figure 16 Shorting Contactor Timing Diagram 1998 Square D All Rights Reserved VD0C32S301B June 1998 Logic Input Logic Outputs Analog Output 1998 Square D All Rights Reserved Chapter 2 Wiring Control Connections The logic input LI may be operated either from the internal supply or an external supply Figure 17 shows the connections for operating the logic input from an internal supply Customer supplied Figure 17 Operating the Logic Inputs from Internal P
53. cates motor status The A1 output can be configured for 0 20 mA or 4 20 mA output The analog output is factory preset to indicate motor current but may be configured to indicate motor torque thermal state or power factor Analog Output Logic Input DISPLAY OF MOTOR VALUES 1998 Square D All Rights Reserved The logic input is factory pre set to force the controller to a freewheel stop Alternate configurations include external fault force to local control control of cascading motors and thermal overload reset Force to Freewheel Overrides controlled deceleration if selected External Fault Interrupts controller operation following an input from an external fault detection device Local Control If using the communications option VW3 G46301 the logic input must be configured for local control When configured for local control activating the logic input is required to switch from remote to local operation Control of Cascading Motors When initiated allows for control of several motors Thermal Overload Reset The logic input may be configured to require operator acknowledgment of a thermal overload condition In this configuration the logic input must be changed to state 1 after the thermal fault has cleared before the motor may be re started Fault Reset The logic input may also be configured to require operator acknowledgement of all faults In this configuration the logic input must be changed to state 1 after a faul
54. e 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 FAULT END HERE Tf startup Figure 14 ATS46 Control Terminal Connections J1 Terminals Table 8 J1 Terminal Connection J2 Terminals TYPE FUNCTION DESCRIPTION Be 8 TERMINAL Controller will allow motor to run when this connection is made to terminal PL Both RUN and STOP connections must be STOP Input Stop removed to initiate a stop command See Figure 15 on page 20 for connection of interlocking contacts if used Controller will start motor when connection is made between this point RUN Input Run and PL This connection may be momentary Controller will respond when connection is LI Configurable Logic Preset for force to made between this point and PL Refer to Input freewheel stop Logic Input on page 11 for available configurations volt supply for use with J1 terminal 24 PL Supply to Inputs connections only Connect to PL or to external 24 volt LO Suppiy lo Logic supply Maximum current with external P supply 200 mA Logic output compatible with PLC input or LO1 Configurable Logic Preset for indication of LED type pilot light May also be Ou
55. eature is typically used in pumping applications to prevent hydraulic shocks or water hammer which may occur if the motor decelerates too quickly As shown in Figure 28 on page 33 when deceleration ramping is selected the ramp time may be adjusted from 1 to 60 seconds The torque threshold at which the ramp ends may also be adjusted from 0 to 100 of nominal torque 1998 Square D All Rights Reserved VD0C32S301B June 1998 InTele Braking MOTOR PROTECTION AND DIAGNOSTICS Thermal Overload Protection 1998 Square D All Rights Reserved Chapter 3 Application and Protection Motor Protection and Diagnostics Once the torque reaches the threshold value the controller changes to freewheel mode and the motor coasts to a stop The threshold setting is useful in pumping applications which do not require continued deceleration control once the check valve has closed If the torque is below the threshold setting at a given stop command controlled deceleration is not activated and the controller changes to freewheel stop Torque 20 threshold j l l l l T l l 0 1 Deceleration setting 60 t s Figure 28 Torque Ramp During Deceleration InTele Braking is available for applications that require faster than freewheel deceleration time Impulse braking decelerates the motor to 20 of the rated speed DC Injection completes the deceleration The braking level may be adjusted from 0 t
56. elay KM1A is required when the KM1 contactor coil exceeds the relay rating KM2 Used for reversing applications only the KM2 must be mechanically interlocked to KM1 A reversing contactor may be KM2A Isolation Contactor Reverse used for the combination of KM1 and KM2 In general the operation of KM2 is identical to KM1 The pilot relay KM1A is required when the KM1 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 speed and voltage The starter provides proper sequencing of this contactor by the end start up relay When the start is KM3 Shorting Contactor amp completed the shorting contactor will be commanded to close The starter will continue to monitor the motor thermal state KM3A Pilot Relay and provide motor overload protection Upon a stop command the KM3 contactor will open transferring the motor current to the SCRs to allow for controlled deceleration if desired The pilot relay KM3A is required when the KM3 contactor coil exceeds the relay rating Refer to Figure 16 on page 20 Transient suppression of all relay and contactor coils except ST is recommended to minimize the possibility of electrical TS Transient Suppressors interference with the starter electronics and to increase relay contact life Used in all non reversing logic optional in shunt trip for proper sequencing of contactor logic When energized RCR RCR Run C
57. elf adjusting Rated current Ici Motor power 17 to 1200 A in 21 ratings 2 to 1000 hp Motor voltage 208 220 230 240 380 440 460 500 V Protection Mains protection Integrated thermal protection for motor and controller Phase failure signaled by LED and output relay Controller stops Thermal switches Three phase supply voltage Controllers rated 75 amps and above have two thermal switches one controlling the fan 50C and one protecting against controller overheating 90C or 105C 208 V 10 to 240 V 10 380 V 15 to 415 V 10 440 V 10 to 500 V 10 Table 4 Control Terminal Blocks J1 Terminals STOP RUN LI Function Stop controller Run controller Logic input assignable Characteristics 3 logic inputs with 1 5 kQ impedance Vmax 30 V Imax 16 5 mA state 1 V gt 11V 1 gt 6mA state 0 V 5V 1 2mA PL Supply to logic inputs 24V 5 V isolated and not protected against short circuits and overloads maximum 60 mA LO Supply to logic outputs Connect to PL or to an external supply LOI LO2 Logic outputs Logic outputs compatible with PLC inputs Vmax 40 V Vmin 10 V maximum current 200 mA with external supply AO1 Analog output 0 20 mA linearity 3 precision 3 maximum impedance 800 Q COM J2 Terminals R1B R1D R1A R1C Logic input logic output and analog output common N C contact of relay
58. ep 3 2 If replacing the SCR pole remove the braided cables and standoffs Use these in the new pole assembly When replacing the braided cables make sure cables are flush with the top side of the channel Otherwise proper conduction may not occur Refer to Figure 56 for assembly of the cable to the channel 3 Replace the red wire that is attached to the mounting bracket of the replacement pole Re tighten screw to maintain proper alignment of bracket 4 Using the free end of the lower braided cable and the mounting bracket handle replace the pole in the controller chassis 5 Replace the removed wire from the pole assembly Tighten the following to 80 Ib in 9 Nem all 10 mm bolts holding the power pole assembly to the chassis all connections to the bus bar 6 Replace the jumper from the current measure board see Figure 57 on page 76 Connect the four wires to the terminal block see Figure 54 on page 74 7 For C79 through M12 controllers tighten to 40 Nem all bolts that connect the poles in parallel Nut Washer Braided Cable Washer Bolt Heatsink Figure 56 Assembly of Braided Cable to Heatsink 1998 Square D All Rights Reserved 75 Chapter 6 Servicing the Controller Replacing the Control Module Current Measurement Board Replacement 76 VD0C32S301B June 1998 The current measurement board located behind the control mounting bracket on the angled part of the controller body takes input from
59. er rated amps the maximum current limit setting would be 500 If using a motor rated for 50 of the controller rating the minimum setting the current limit may be set as high as 700 For constant torque or high performance applications the performance of the ALTISTART 46 controller may be optimized by the following steps 1 Measure load requirements Set controller to monitor load torque LTR Start the motor with the factory default settings Load the motor to the maximum continuous load torque for the application Read the measured torque LTR for continuous duty normal speed e Stop the motor 2 Adjust the controller a Setthe current limit ILT to the maximum setting to provide the maximum Starting torque b Set the initial torque tq0 and torque limit LI to 120 of the measured load requirements For example if LTR 50 set 100 and tLI to 60 3 Optimize the application a Issue a run command If the motor starts reduce the stator loss compensation LSC by 10 Repeat until the motor no longer starts then increase by 10 The application is then optimized to within 10 b If the motor does not start increase the stator loss compensation LSC by 10 Repeat until the motor starts The application is then optimized to within 10 53 Chapter 4 Controller Setup and Operation VD0C32S301B Adjusting Controller Settings June 1998 54 1998 Square D All Rights Reserved VD0C32S301B Chapter 5
60. ermal overload fault or equipment damage The following conditions can cause excessive heating Excessive duty cycle more than 6 evenly spaced starts per hour Excessive acceleration ramp due to high inertia loads High ambient temperature Check with the motor manufacturer for the motor s suitability for operation on a solid state reduced voltage controller configured for your application Motor thermal sensors built into the motor windings and connected through the control logic may be required for motor protection Specific application duty motors such as explosion proof and submersible motors will require enhanced protection and special considerations in application The motor manufacturer MUST be consulted when applying these motors Failure to follow this instruction can result in injury or equipment damage 52 1998 Square D All Rights Reserved VD0C32S301B June 1998 Setting the Current Limit Advanced Acceleration Ramp Adjustments 1998 Square D All Rights Reserved Chapter 4 Controller Setup and Operation Adjusting Controller Settings The current limit is expressed as a percentage of the setting and is adjustable from 150 to 700 However the maximum starting current is limited to 500 of the controller rated current The peak amperage drawn using the current limit feature can be determined by the following formula VIE OM te gt 0 n For example if the motor FLA equals the controll
61. ex key to remove the power straps which connect the SCRs to the line and load terminals e For C17 through C32 controllers first remove the filter card see page 10 Then remove the bus bar connections using a 10 mm socket wrench two bolts per phase 3 Using an Allen wrench remove the four screws at the base of the SCR module which hold the SCR to the heatsink To replace the SCR module follow these steps 1 Apply a thin coat of thermal grease e g Alcoa 2EJC or equivalent between the heatsink and SCR for better heat transfer NOTE Do not allow grease to go into the threaded hole 2 Install the new SCR module applying the proper torque to the screws holding the SCR to the heatsink and to the bolts connecting the power straps or bus bar to the SCR Table 20 lists the proper tightening torque for the SCR connections 3 Reconnect electrical leads to the SCR module in their original positions Table 20 Tightening Torques Tightening Torque Ib in Nem ATS46 SCR Part Number Case to Heatsink Case to Bus Bar D17N VZ3TM2026M16 57 5 6 5 22 2 5 D22 D32N VZ3TM2055M16 57 5 6 5 22 2 5 D38N VZ3TM2090M16 57 5 6 5 22 2 5 D47 D88N VZ3TM2130M16 57 5 6 5 40 4 5 C11N VZ3TM2160M1601 57 5 6 5 57 5 6 5 C14 C25N VZ3TM2250M16 57 5 6 5 75 8 5 C32N VZ3TM1400M16 57 5 6 5 75 8 5 Case to power strap bus bar connections pu uh er Bus strap for dual pak SCRs Gate connections
62. formation The ATS46C79 through M12 controllers use two SCR power poles connected in parallel If an SCR in either pole is shorted replace both poles in the SCR assembly To replace the SCR package interface board or thermal switches remove the entire power pole assembly Removal allows easier access to the individual components Note the location of each wire as you remove the assembly The interconnections between the SCR pole and firing interface board are not labeled To remove the power pole assembly from the controller chassis follow these steps 1 Remove the control module as described on page 67 2 Either rotate the control module mounting panel or remove it Either action allows access to the SCR poles current measurement board and control power transformer 3 Disconnect the jumper to the interface card from the current measurement board The label designation from J4 to J9 depends on which pole the jumper connects to 4 To remove the SCR pole assembly disconnect the wires and remove the bolts indicated in Figure 54 Use a 10 mm wrench to remove the bolts 5 Cut wire ties from the power pole assembly to the insulating wall 6 Pull the SCR pole assembly from the controller chassis using the handle on the mounting bracket C in Figure 54 and the free end of the lower braided cable Bolts remove these Bolts do not remove these Holding bracket Interface board Shorting contactor connection Line connecti
63. he 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 in the same conduit this separation reduces the possibility of coupling electrical noise between circuits When wiring ATS46 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 8 cm 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 30 5 cm Cross the metallic conduits and non metallic conduits at right angles whenever power and control wiring cross The control circuit is completely independent of the power circuit To select control voltage follow the instructions on the label located on the top of the controller 208 240 V move terminal cover from position 230 to position 460 500 V and connect single phase voltage supply to terminals C and 230 V 880 415 V move terminal cover from position 400 to position 460 500 V and connect single phase voltage supply to terminals C and 400 V 440 500 V check that exposed control terminals are marked C and 460 500 V If not move blue terminal co
64. hermal state 0 to 250 f selected the motor thermal state is displayed expressed as a percentage of the normal operating temperature LPr Active Power 0 to 250 of the nominal motor power f selected the active power of the motor during acceleration deceleration and steady state operation is displayed The active power is displayed as a percentage of the motor nominal power LE Motor load state 0 to 250 of the nominal motor torque f selected the motor load state during acceleration deceleration and steady state operation is displayed The load state is expressed as a percentage of the motor nominal torque Motor current 0 to 6000 amps f selected the motor current during acceleration deceleration and steady state operation is displayed If the current is less than 1000 amps the current is displayed in amps If the current is greater than 1000 amps the current is displayed in kiloamps For example 1 5 amps is displayed as 5 78 6 amps is displayed as 74 5 384 amps is displayed as 3 E 4 1255 amps is displayed as 25 ray Controller status rd run or fault status After control power is applied the display is blank for a brief period while the controller performs self diagnostics If all is clear the 4 4 or ready controller status is displayed The display changes to r u n once a start command is given The r u n display flashes during acceleration deceleration and br
65. igned L A freewheel stop 1E external fault 1H reserved IL local control 1L control of cascading motors reserved 1E motor overload reset Ir fault reset DIRR Assignment of LO1 aFF ER I nni EH The following settings are available for assigning logic output LO1 E A 1 motor thermal alarm r n motor powered Current trip threshold 50 to 300 of I This alarm is only active during steady state operation An overcurrent condition in relation to the threshold that has been set must last 10 seconds to activate alarm LO2 If a short overcurrent condition occurs and the current returns to a value 10 below the user defined threshold the overcurrent detection is reset Detection of continuous and brief overcurrent conditions is shown in Figure 36 on page 42 Phr Detection of phase rotation FF deaa Tu BFF Checks the direction of phase rotation in the mains supply If the supply does not correspond to the selection the controller changes to fault state PIF This function is only activated if a run request is issued Assignment of relay R1 C COURSE uL The following settings are available for assigning relay R1 r IF fault relay r l isolation relay controls a line contactor rEh Reset of motor thermal state na HES5 na After a request to reset the motor thermal state parameter amp h returns to no Using this parameter should be l
66. imited to maintenance operations changing motor starter etc Int Return to factory setting C na HES5 The parameter automatically returns to the factory setting After a request to return to factory settings r E returns to n a ELA Adjustment of braking time 0 to 100 ru a If braking E is selected adjusts the motor stop time after the impulse braking phase Aa Assignment of analog output AO1 oFF Her HEr HEh HLEHU The following settings are available for assigning analog output AO1 OF F not assigned Hc r motor current HE r motor torque H E h motor thermal state AL power factor Output can be configured to 0 20 mA or 4 20 mA using the parameter 0 4 and can be scaled using A5c H5c Scaling of analog output A01 50 500 oo Adjusts from 50 to 500 of the selected value 20 mA corresponds to full scale 1998 Square D All Rights Reserved 51 Chapter 4 Controller Setup and Operation VD0C32S301B Adjusting Controller Settings June 1998 Table 17 Level 3 Parameters Continued Parameter Type Adjustment Range Preset Description Checks the controller in a test or maintenance environment without having to use a motor with a motor power rating equivalent to that of the controller esp high powered controllers Torque control L P is automatically disabled when using 552 5 5 Test on low
67. in components that can be potentially hazardous to maintenance PRECAUTIONS personnel Semiconductor devices can exhibit hazardous leakage currents in the off state Personnel performing parts replacement should be thoroughly familiar with ANSI NFPA 70E Follow these safety measures 1 Verify that the equipment has been installed and applied in a manner that is consistent with the information in the equipment instruction manual applicable code requirements and regulations 2 Coordinate all parts replacement procedures with the operations manager of the facility 3 Ensure that the controlled equipment is disconnected from the controller or that access to it is prohibited 4 Read all precautions in this manual that relate to the procedure being followed 5 Make sure you are familiar with the tools and instruments required for the specific procedures described in this chapter 6 Ensure that you have proper body protection clothing eye protection helmet and other safety gear 7 Ensure that electrical equipment surrounding the controller is either de energized or isolated in such a way that maintenance personnel are not subject to electrical shock 64 1998 Square D All Rights Reserved VD0C32S301B June 1998 LIST OF TOOLS AND INSTRUMENTS STANDARDS 1998 Square D All Rights Reserved Chapter 6 Servicing the Controller Standards 8 Ensure that all power sources feeding the controller are de energized and locked
68. ion Adjusting Controller Settings At any time the user may select which parameter is to be displayed If the motor is idle the next time the motor is started the selected motor starting parameter is displayed If the motor is running while the adjustment is made the desired monitoring parameter is displayed after pressing the DATA pushbutton Indicates the motor current value if gt IU gt the controller is enabled using a run command E Controller not enabled no run command 0 DATA 0 mum BHE gt Indicates that a fault is present e g PhF A ray DATA Monitoring motor current Ler and torque Ltr b gt log Indicates value of the motor L 3 DATA thermal state rdH Monitoring motor thermal state Lth and power factor cos Figure 39 Displaying the Monitoring Parameters Control parameters consist of configuration and adjustment parameters Configuration parameters indicate the type of control or on off selections and can only be modified when the controller is in a ready status Adjustment parameters are functions that have an adjustment range or level and can be modified at any time in setup mode For example the type of deceleration control is a configuration parameter and cannot be changed once the motor is operating However the deceleration ramp time is an adjustment
69. k of Module Figure 45 Replacing the Control Module Front of Module To replace the control module follow these steps 1 Install the electrical connections Push all connectors so that they are firmly in place 2 Mount the control module to the power section Carefully secure all wires in the controller to prevent damage to the wire or loosening of the connections 3 Retighten the four holding screws NOTES When the control module is damaged the entire module must be replaced Any attempt to access repair or inspect the control module s circuit boards voids the product warranty When replacing the control module note that the replacement control module does not include the operator interface keypad or communications module The user must purchase a replacement operator interface separately 67 Chapter 6 Servicing the Controller Replacing the Control Module POWER SECTION REPAIR ATS46D17 TO C32 CONTROLLERS 68 VD0C32S301B June 1998 The control module must be removed to repair the components in the power section The ATS 46 product line consists of five frame sizes which share common power section design The replacement process for the power components is similar for units within a frame size For units rated 17 through 320 amps remove the control module and protective housing to access the power components directly These items are replaceable in the power section of the 17 through 320 A models D17 to C32
70. l torque ha setting and the slope indicated by the A c c define the motor EB que torque ya A ie id A MAS Neg 10 starting performance The starting performance may be starting Level 2 only nominacmeterterque optimized by adjusting the initial torque setting without modifying the slope of the ramp Limitation GE maximum Limits the peak torque provided by the motor Primarily used EL 1 torque A 10 to 200 of measured GEE to limit acceleration of high inertia applications the torque limit Level 2 only nominal motor torque combines with the slope and initial torque settings to provide a customized torque profile An underload threshold can be set to prevent damage to the driven machinery or process resulting from an underload condition i e dry pump condition The underload detection Motor underload is only active during steady state operation N ULL threshold 6 20 to 100 of measured GEE To prevent nuisance tripping the underload condition must Level 2 only nominal motor torque last for 4 seconds If a short underload condition occurs and loading returns to a value 10 above the user defined threshold the underload detection is reset Detection of continuous and brief underload conditions is shown in Figure 37 on page 43 Maximum start time Compares the motor acceleration time to the time set using ELS Level 2 only 0 10 to 999 seconds afF E L 5 Ifthe time is exceeded the controller changes to a fault state of stF The thermal overload clas
71. llers 66 SCR Replacement 67 Filter Card Replacement 69 Thermal Switch and Fan Replacement 69 Control Power Transformer CPT Replacement 70 POWER SECTION REPAIR 2 4 eet eee 71 ATS46C41N to M12 Controllers 71 SCR Power Pole Assembly 71 Firing Interface Board Replacement 72 Current Measurement Board Replacement 74 Thermal Switch Replacement 75 Fan Replacement 4 i 3 EW Ae EE al E eee nen 75 Control Power Transformer Replacement 75 63 Chapter 6 Servicing the Controller VD0C32S301B Introduction June 1998 INTRODUCTION For the protection of personnel and equipment a qualified maintenance person must perform the procedures detailed in this manual The maintenance person should Read interpret and follow instructions and precautions in this manual and the other manuals referenced Use the tools listed on page 65 of this manual in a safe and technically correct manner Perform troubleshooting and parts replacement procedures while following the safety procedures recommended in ANSI NFPA 70E Be trained o
72. m LED PROG Data Pushbutton Program Push 2 Holding Screw Pa Scroll Forward mm MN et j utton Figure 37 Front Panel of Keypad Selecting a Menu Level Scroll Backward Pushbutton Using the Keypad The adjustable parameters are separated into three levels Two switches on the back of the display keypad can be adjusted to provide access to all three programming levels or prevent adjustment to the controller To avoid accidental controller modifications the controller is preset Adjustment cannot occur without first removing the keypad and changing the dip switch setting Refer to Figure 38 69 Switches for selecting a Menu Level a Figure 38 Rear Panel of Keypad When Controller is Ready When Motor is Running Table 13 Setup Mode Switch Position Level 1 2 Basic acceleration SI e 1 ON P Level 2 Includes level 1 2 parameters and ON 1 additional set up of more advanced features Level 3 2 Reconfiguration of 1 controller operation ON _ independent of level 1 and 2 parameters Controller may be start ed and stopped with presence of run com mand Display of monitoring parameters level 1 amp 2 only Display and modification of adjustment parame ters Dis
73. mages 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 33 Chapter 3 Application and Protection Motor Protection and Diagnostics 34 VD0C32S301B June 1998 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 t 60 mn 5 mn Ti Pre alarm Vin Figure 30 Thermal Trip Curves The ATS46 controller is preset to provide Class 10 overload protection for standard duty applications The ATS46 controller can be adjusted to provide Class 2 10A 10 15 20 25 or 30 overload protection as necessary Class 2 protection is available for applications such as submersible pumps where very tight control of motor temperature is reguired Class 30 protection is available for applications such as high inertia loading where a longer than normal starting time is reguired to accelerate the load to full speed In addition the internal overload protection may be disabled if motor protection is provided
74. mpedance ground fault Failure to follow this instruction can result in death or serious injury 1998 Square D All Rights Reserved 11 Chapter 1 Receiving and Installation Mounting Precautions MOUNTING PRECAUTIONS Mounting in General Purpose Metal Enclosure 12 VD0C32S301B June 1998 Follow these precautions when mounting the ATS46 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 664 1 A DANGER HAZARDOUS VOLTAGE ATS6 controllers are open devices and must be mounted in a suitable enclosure Electrical shock will result in death or serious injury When 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 in an enclosure cover the device to prevent metallic debris from falling into the controller The ATS46 controller generates heat and must be properly ventilated Refer to Thermal Considerations for Sizing Enclosures on page 13 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 con
75. n the operation and fundamentals of AC controllers and systems and be familiar with the associated hazards Review the sections below for personnel and equipment protection precautions before performing parts replacement procedures A DANGER HAZARDOUS VOLTAGE Read and understand this section before maintaining or servicing the ALTISTART 46 controller Only qualified personnel should install adjust service and maintain these controllers Confirm that controller has been correctly selected installed and applied before performing any service or maintenance Verify that all controller overcurrent protective devices conductors enclosures and other circuit elements have been correctly selected for application and that controller is properly grounded in accordance with equipment instruction bulletin recommendations and applicable code requirements Many parts in this controller including printed circuit boards operate at line voltage DO NOT TOUCH Use personal protective equipment and follow precautions and measurement procedures referenced in this bulletin when making any measurements on energized equipment Use instruments and insulated tools approved for job Install all covers before applying power or starting and stopping controller Observe and follow all applicable lock out and tag out procedures for specific installation Electrical shock will result in death or serious injury PERSONNEL PROTECTION ATS46 controllers conta
76. nclude grinders crushers and presses as well as high inertia fans and saws For heavy duty applications the controller must be de rated by one size When the duty selector switch is toggled to heavy duty mode the default motor current setting is adjusted to the rated current of the next lower common motor size At the heavy duty default settings 5 starts per hour may be achieved for a maximum of 46 seconds per start without tripping If a shorting contactor is used to bypass the SCRs after starting the controller may be used for heavy duty applications at its standard duty rating Refer to chapter 3 for additional information regarding the factory presets The asynchronous motor associated with the ATS46 controller 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 will draw is reduced by the ratio of the voltage applied The torque produced by a motor varies with the square of the voltage at a fixed frequency The resultant torque produced by a motor then varies with the square of the voltage at a fixed frequency Figure 23 shows the speed torque characteristics as a function of the supply voltage Torque Tload Rated 0 025 05 0 75 1 Speed Tas Torque developed at full voltage 1 T 2 Ti Torque developed with reduced voltage d1 dy Va Nominal voltage V Reduced voltage Figure 23
77. nd J5 J7 J9 on C79 M12 controllers From CTs on T2 and T3 To thermal Control switch Module From control power transformer To control module Figure 58 Current Measurement Board 1998 Square D All Rights Reserved VD0C32S301B June 1998 Thermal Switch Replacement Fan Replacement Control Power Transformer Replacement 1998 Square D All Rights Reserved Chapter 6 Servicing the Controller Replacing the Control Module To replace the current measurement board follow these steps 1 Mount the board to the controller Tighten the holding screws 2 Reconnect all jumpers to the measurement board 3 If plugs were removed reconnect plugs on the end of the wires opposite the control module and SCR poles NOTE The power section of the ATS46C79 through M12 controllers uses two power sections connected in parallel The replacement instructions are the same for the C79 to M12 controllers except for pole connections Figure 53 on page 73 shows pole connections for the C41 through M12N The thermal switches from each pole are connected in series for operation of the fan and indication of heatsink over temperature When replacing the thermal switch note the location of the existing switch connection to the terminal block This connection on the pole assembly is critical to proper operation of the fan and thermal alarm On the ATS46C41 through M12 controllers there are thermal switches for fan control and detecti
78. ndicator lamp flashing Awaiting validation PROG button or cancellation DATA button of modification of the parameter value Figure 41 Displaying Modifying the Control Parameters While in Setup Mode 46 1998 Square D All Rights Reserved VD0C32S301B June 1998 Parameter Flowcharts 1998 Square D All Rights Reserved Chapter 4 Controller Setup and Operation Adjusting Controller Settings ATS46 controller setup is accomplished using the keypad as described in Using the keypad on page 42 The flowcharts displayed in Figures 42 43 and 44 list the order in which the parameters appear when scrolling through the menus Tables 16 and 17 provide the description adjustment range and factory preset for each parameter When control power is first applied the pointer is on rd ler for levels 1 and 2 Pressing positions the pointer on the parameter Pressing W positions the pointer on the EEE Monitoring parameter Adjustment parameter In parameter Selection of stop type Configuration parameter r in or Figure 42 Level 1 Parameters 47 Chapter 4 Controller Setup and Operation VD0C32S301B Adjusting Controller Settings June 1998 A When control power is first applied the pointer is on g yJo
79. ng The tools and instruments required to perform maintenance and replace components on the ATS46 controller are listed below Set of magnetized flat blade screw drivers Set of magnetized phillips screw drivers Set of Torx screw drivers 1 4 drive metric socket set 5 5 to 14 mm One 2 1 4 drive socket extension One 2 1 4 drive socket extension Metric hex key set 2 to 14 mm Regular hex key set 1 4 to 9 16 Metric ball end hex key set 2 to 14 mm Torque wrench 4 4 to 352 Ib in 0 5 to 40 Nem Metric hex key sockets for torque wrench Metric drive sockets for torque wrench Thermal grease Alcoa 2EJC or equivalent Set of open box end wrenches 5 5 to 19 mm Multimeter 0 1000 V Fluke 87 or equivalent Clamp On Current Probe 0 600 A Fluke 80i 600A or equivalent Connector Extractor This manual references the latest revision of the following standards ANSI NFPA 70B Electrical Equipment Maintenance ANSI NFPA 70E Electrical Safety Requirements for Employee Workplaces NEMA ICS 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control NEMA ICS 1 3 Preventive Maintenance of Industrial Control and Systems Equipment NEMA ICS 2 Annex A Maintenance of Motor Controllers After a Fault Condition OSHA 29 CFR Part 1910 Electrical Safety Related Work Practices 65 Chapter 6 Servicing the Controller Standards PARTS REPLACEMENT 66 VD0C32S301B June 1998 This
80. o 100 to provide gradual ramp To customize the deceleration ramp adjust the duration of the DC injection from 20 to 10096 of the impulse braking time If InTele Braking is selected the controller is preset for 5096 braking torque level with a change to DC injection at 2096 speed for 20 duration Speed 4 100 96 Less gradual braking More gradual braking Level to switch to DC injection Time Impulse braking DC injection Figure 29 InTele Braking The ATS46 controller provides state of the art motor protection On controllers rated 47 A and higher motor protective features are available even if a shorting 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 ATS46 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 30 shows the ATS46 controller creates a digital model of the motor temperature based on two thermal i
81. of interrupting 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 A WARNING BRANCH CIRCUIT CONDUCTOR HAZARD If System grounding is not adequate to ensure ground fault levels exceed 1300 of motor full load amps FLA then this device may not ensure protection of 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 Fuses listed in Recommended Component List on page 26 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 Equipment ground fault protection If using a circuit breaker or fuses sized larger than 125 of motor FLA as OCPD an external ground fault relay or circuit breaker with ground fault detection should be coordinated with controller An application diagram showing coordination of an equipment ground fault relay is shown in Figure 20 on page 22 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 i
82. ommand Rela initiates the start sequence When de energized stopping is initiated Operator controls can be either on off selector y Switch HOA selector switch or start stop push buttons RCR remains energized during a fault Once the fault condition has been cleared RCR must be de energized by a stop command then re energized to restart the controller Used for reversing applications only this coil duplicates the functionality of RCR for the forward direction and is interlocked RFR Run Forward Relay with the RFR relay Run Reverse Relay Used for reversing applications only this coil duplicates the functionality of RCR for the reverse direction and is interlocked with the RRR relay This coil is attached to the shunt trip coil on the disconnect and will energize 2 seconds after a starter fault by the TR timer ST Shunt Trip Coil 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 starter fault Used with logic diagrams that use an isolation contactor The fault relay is energized during normal operation and de FR Fault Relay energizes if the starter fault contacts open or if the motor thermal switch if supplied opens FR also provides additional contacts for the starter fault output GFR Ground Fault Relay Current sensitive relay for detection of ground current If
83. on Braided cables Fan switch connections TOTMUODP Figure 54 SCR Power Pole Assembly After removing the power pole assembly from the chassis replace the SCR pole interface board or thermal switches To replace the firing interface board follow these steps 1 Label the wires connected to the interface board for easier identification when reassembling Using a flat head screwdriver remove the seven screws holding red and white wires 2 While holding interface board to pole assembly remove two mounting screws and bolt on mounting bracket 3 Reassemble pole by following step 2 then 1 Tighten the mounting bolts to 40 Ib in 4 5 Nem In order for the controller to operate properly the SCR firing circuits must be properly connected Use Figure 55 on page 75 to identify the location of each wire 1998 Square D All Rights Reserved VD0C32S301B Chapter 6 Servicing the Controller June 1998 Replacing the Control Module A to top of upper braided cable B to top mounting bracket C to bottom of upper braided cable D in black tubing from upper SCR E in white or yellow tubing from lower SCR Figure 55 Interface Board Connections To replace the power pole assembly on the controller chassis follow these steps 1 If replacing only the thermal switch or interface board re assemble the components to complete the power pole assembly Complete this step before mounting the pole back in the controller chassis Skip to st
84. on of the heatsink temperature on each power pole assembly The SCR power poles must be removed to gain access to the thermal switches Use the same fan replacement in the ATS46C41 through M12 controllers as for the ATS46C14 through C30 controllers Refer to page 77 for fan replacement instructions On C79 through M12 controllers each fan operates independently based on the left and right side temperature Control power transformer replacement for ATS46C41 through M12 controllers is the same as for ATS46C17 through C32 controllers Refer to page 72 for CPT replacement instructions CAUTION EQUIPMENT DAMAGE After completing any repair of the ALTISTART controller ensure that all power connections are properly tightened and that the starter programming meets the application requirements Do not substitute SAE or alternate fasteners Failure to follow this instruction can result in injury or equipment damage For additional assistance with replacing components or troubleshooting the ALTISTART controller contact your local Square D Field Sales office Square D Technical Services Department 800 634 2003 or the Square D Drives Product Support Group 919 217 6536 77 Chapter 6 Servicing the Controller VD0C32S301B Replacing the Control Module June 1998 78 1998 Square D All Rights Reserved Table 20 Controller Motor Combinations ATS46 Model R
85. oo PRE Ci SS o a a l FAULT A E pen RIA RIC ES FAULT IT Ca 7 RELAY TS1 de Ren ARS ISOLATION t Ene Nae CONTACTOR O Control circuit connected for 460 V operation O TS2 Reconnect as reguired for other voltages END START UP E 2 Shorting contactor terminals not provided on D17 D22 RA RIG 9 SHORTING D32 or D38 controllers ER EE EE atl EE o L o e KM3A I 8 B NL ND E PILOT RELAY 1 l oe l 3 For optional shorting contactor operation with D47N through M12N L tsi L controllers add KM3 with associated control circuit i AU D SHORTING oh Stee ore 1 KM9 CONTACTOR Relay contact located on ATS controller M Nr 7 T EE sk i G Located at motor Jumper if switch not present j j CAR K I PUS i aoc 2232022 Lu SS mee 4 B l e POWER ON For D47 through C11 controllers using a shorting contactor 1 eae j pilot relay KM3A is not required Substitute coil of KM3 contactor 1 ER I in place of KM3A pilot relay j FR Bis TEC ji O eere mcd Gl EIE 2 w nn FAULT Set RCR time slightly longer than the expected deceleration 1 41 1 time from rated speed to zero speed The time delay RCR contact may I ISEN j be omitted if the configuration of the R1 relay is changed to isolation KM1 e j contactor control Poe j Aa SEK 1L 4 G Bestel RUN AA 2 WIRE CONT
86. ower Supply The logic outputs LO LO1 LO2 can be operated from either the internal supply or an external supply The maximum current with external supply is limited to 200 mA If the internal supply is used LO must be connected to PL Figure 18 shows the connection of an external supply for operating the logic outputs 2 Customer supplied Figure 18 Operating the Logic Outputs from External Power Supply The analog output AO1 can be configured for 0 20 or 4 20 mA output of the motor current torque thermal state or power factor Refer to Chapter 3 for configuration of the analog output The maximum driving voltage is 12 V with an internal impedance of 800 Q Figure 19shows the connection of an external meter to the analog output 0 20 mA or 4 20 mA A 800 Q Customer supplied Figure 19 Analog Outputs 21 Chapter 2 Wiring Control Circuit Diagrams CONTROL CIRCUIT DIAGRAMS VD0C32S301B June 1998 The following figures are shown for 2 and 3 wire control of non reversing and reversing applications Recommended circuit diagrams include SCR fault isolation for optimal protection of the motor driven machinery and operating personnel Circuit Breaker 5 w Shunt Trip Coil CIT JO Ground Fault AGFR is not required if OCPD is sized for protection of branch circuit conductors see Table 5 on page 26 27 Relay GFRA JO O 7O
87. parameter and may be adjusted at any time in setup mode If adjusted prior to a stop command the deceleration time adjusts to the new setting at the next stop command 45 Chapter 4 Controller Setup and Operation Adjusting Controller Settings When control power is applied r d H indicates controller is ready if line power is not present nL F indicates controller is ready Controller ready E or rd j n L P default pointer position 1 gt aa lt mm mim A REE VD0C32S301B June 1998 Lockout mode U m 2 L NM ON Switch on the back of the keypad Note In lockout mode parameters can be displayed but not modified Figure 40 Displaying the Control Parameters While in Lockout Mode Controller ready r d 9 n L F default pointer position v Setup mode mm 2 Search for ILE mu 14 Levi parameter mm ON to modify v Acc io DATA an man mi Leva A ON lt t y 20 Modification mm of setting or mum A mH 2 configuration x DATA Ua 1 Lev 3 5 ON 4 Y PROG Indicator lamp on E 69 setup mode PROG j gt r MIRI 30 i d mca SEY Y I
88. peed and opens following a fault condition or after a stop command is initiated Following a stop command the end of start up contact is used to drop out the shorting contactor so that deceleration control may be used if selected If a shorting contactor is going to be used to bypass the SCRs after starting is complete the shorting contactor must close within 500 msec of detection of full speed operation If a shorting contactor is used the end of start up relay must be used to coordinate operation of the shorting contactor Two logic outputs compatible with PLC inputs are provided on the ATS46 controller The factory preset for LO1 indicates a thermal pre alarm In this configuration the logic output changes to state 1 when a motor thermal overload pre alarm has been reached and stays high until the thermal fault has cleared When a pre alarm condition exists corrections should be made to the process to prevent an actual overload fault condition which requires down time for motor cooling The LO1 output may also be configured for motor power indication In this configuration the output changes to state 1 whenever the motor current is present A second logic output LO2 is provided to signal an overcurrent alarm If overcurrent detection is not selected LO2 is inactive 1998 Square D All Rights Reserved VD0C32S301B June 1998 Chapter 3 Application and Protection Display of Motor Values An analog output is provided that indi
89. play and modification of configuration param eters Display of fault codes Prog LED lit Display of monitoring pa rameters Display and modification of adjustment parameters Display of configuration parameters no modifica tion of configuration pa rameters 1998 Square D All Rights Reserved 43 Chapter 4 Controller Setup and Operation Using the Keypad Operating the Pushbuttons 44 Table 14 Adjustment Lockout Mode VD0C32S301B June 1998 Switch Position When Controller is Ready or Motor is Running Controller may be started and stopped with presence Caw 2 of run command LN 1 Level 0 FS ON Operating Mode Display monitoring parameters No adjustment Display of Level 2 parameters and settings possible Display of fault codes No modifications possible Operation Key When parameter name is displayed When parameter value is displayed Steps forward through parameter list Increases parameter value Steps backward through parameter list Decreases parameter value DATA Displays parameter value Displays parameter name or cancels change to parameter value PROG i 1 4 Saves change to parameter value 1998 Square D All Rights Reserved VD0C32S301B June 1998 ADJUSTING CONTROLLER SETTINGS Control Parameters 1998 Square D All Rights Reserved Chapter 4 Controller Setup and Operat
90. power motor C amp n eFF aFF Signals the operation of cascading motors TCS L 5L Cascade operation 0 a r a FF HEF ramp is inactive in this mode because the motor power does not match the controller rating Indicates the operating time in hours since the last reset Elapsed time includes starting running and Fr Elapsed time C an oFF OFF stopping time May only be reset using one of the line communication options VW3G46104 PC software or VW3G46301 PLC communication The time after a STOP command in freewheel mode E b Time before starting 0 0 9 8 or after the end of ramp or braking before a new START command will be accepted Type Abbreviations A Adjustment C Configuration Setting the Motor Current The motor nominal current l4 is factory preset to the values listed in Table 16 on page 50 If the preset value is not within 95 105 of the motor nameplate current or if using a 1 0 service factor motor the 1 parameter should be adjusted as follows Service Factor Setting 1 0 0 96 x Nameplate Current 1 15 or 1 25 I 1 00 x Nameplate Current For 1 15 or 1 25 service factor motors the nominal current may be set as high as 104 of the nameplate current if required to prevent nuisance tripping A CAUTION MOTOR OVERHEATING Motor current draw above nameplate rating will result in motor temperature rise Extended exposure to overcurrents will cause the motor to overheat resulting in th
91. r n 1 p for levels 1 and 2 Cas Pressing 4 positions the pointer on the L c r parameter L L m Pressing W positions the pointer on the A In parameter LPr A A Ler A rd Monitoring parameter v Adjustment parameter ln i v Configuration parameter PEGE Selection of stop type v Er E v SEY v yd zb ES el E 2 v Ede br v v v EHP ESE v v L5 ERD N v v ES ULL 48 Figure 43 Level 2 Parameters 1998 Square D All Rights Reserved VD0C32S301B June 1998 Chapter 4 Controller Setup and Operation Adjusting Controller Settings When control power is L LE first applied the pointer is Hr 5 E b 5 LE IL re res IL v CLP 5 5 E v v L 51 ASE v v Hu Ha v v L I ELA v v La l ln E v v let FER AE Monitoring parameter v v Adjustment parameter nm 3 v ex Configuration parameter P h p Figure 44 Level 3 Parameters Table 15 Monitoring Parameters Monitoring Parameters Display Range Description Las Motor power factor 0 1 to 1 If selected indicates the power factor of the motor while running LEK Motor t
92. r Electric S A InTele Braking is a registered trademark of Square D Company Bulletin No VD0C32S301B June 1998 CHAPTER 1 RECEIVING AND INSTALLATION CHAPTER 2 WIRING CHAPTER 3 APPLICATION AND PROTECTION 1998 Square D All Rights Reserved ALTISTART 46 Soft Start Controller Contents INTRODUCTION EE EER ER WI ba ne ce Pare ele 2 Definition Of Terms sk en rtc Re eR ROER ke a Sed tied 2 TECHNICAL CHARACTERISTICS 2 DIMENSIONS AND WEIGHTS 4 HANDLING THE CONTROLLER 8 SERIAL AND MODEL NUMBERS 8 INSTALLATION PRECAUTIONS 9 MOUNTING PRECAUTIONS 12 Mounting in General Purpose Metal Enclosure 12 Mounting in Dust and Damp proof Metal Enclosure 13 Thermal Considerations for Sizing Enclosures 13 MIRING x rend estes n AA RR ROUEN ia 16 General Wiring Practices 16 Adaptation to Line Input 16 Power Connections 16 Buis Connection ect iiia desee A ge NR E dE xs 18 CONTROL CONNECTIONS
93. r after 60 seconds If the fault has not cleared after 6 successive attempts the fault must then be reset by cycling control power A manual restart is required following a Type 3 fault A WARNING UNINTENDED EQUIPMENT ACTION Automatic restart can only be used for machines or installations that present no danger for personnel or equipment in the event of automatic restarting Equipment operation must conform with national and local safety regulations Failure to follow this instruction can result in death or serious injury Table 18 Fault Definitions To Restart Motor Code Description Refer to Page Cycle Control Power Manual Restart Auto Restart Type Och Overcurrent fault 61 InF Internal failure fault 61 X PF Phase inversion fault 61 PHF Phase fault 58 X X 1 Fre Frequency fault 58 USF Supply fault 59 X X 2 u FU Motor thermal fault 59 h F Starter thermal fault 59 LrF Locked rotor fault 59 ULF Motor underload 60 X 3 SEF Max start time exceeded 60 EEF External fault 60 SLF Serial link fault 60 1 If LI is configured for motor overload reset Lit operator acknowledgment of the overload condition is required The overload must also be reset through the logic input after the fault has cleared before restarting the motor 1998 Square D All Rights Reserved 57 Chapter 5 Fault Management Troubleshooting Faults TROUBLESHOOTING FAULTS Phase Fault Frequency Fault 58
94. re 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 provides accurate controller setup and continuous motor performance display The ATS46 motor controller is available in 21 current ratings from 17 to 1200 amps All models use a common control module for consistent and simple set up ATS46 controllers are rated for use with 208 230 380 400 or 460 500 V motors and are self adjusting for a 50 or 60 Hz supply frequency Some of the terms and acronyms used in this manual are defined in Table 1 Table 1 Definition of Terms Term Definition FLA Full load amps the current rating of an induction motor at rated speed and load This value may be found on the motor nameplate let Nominal current rating of the ATS46 controller This value may be found on the controller nameplate In User defined motor current rating Same as FLA Ta Nominal motor torque as calculated by ATS46 controller V Nominal voltage of supply power mains supply This should correspond to the motor rated voltage n found on the motor nameplate The following tables describe the technical characteristics of the ALTISTART 46 Table 2 Environmental Characteristics IP 20 ATS
95. relay is energized operation of the controller is interrupted by placing in series with the run control relay 1998 Square D All Rights Reserved 25 Chapter 2 Wiring Circuit Diagrams VD0C32S301B June 1998 Table 11 Recommended Component List Induction Motor ALTISTART Controller M ATS FU1 FU2 Rated HPI ATS46 Rated Current ATS Control Class CC Control Fuse Size 208V 230V 460V Model 40012 Power Burden 208 230V 460V 3 5 10 ATS46 D17N 17 20VA 1 4 1 4 5 7 5 15 ATS46 D22N 22 20VA 1 4 1 4 7 5 10 20 ATS46 D32N 32 20VA 1 4 1 4 10 25 ATS46 D38N 38 20VA 1 4 1 4 15 30 ATS46 D47N 47 20VA 1 4 1 4 15 20 40 ATS46 D62N 62 70VA 1 4 1 4 20 25 50 ATS46 D75N 75 70VA 1 2 1 4 25 30 60 ATS46 D88N 88 70VA 1 2 1 4 30 40 75 ATS46 C11N 110 70VA 1 2 1 4 40 50 100 ATS46 C14N 145 70VA 1 2 1 4 50 60 125 ATS46 C17N 176 250VA 1 6 0 8 60 75 150 ATS46 C21N 210 250VA 1 6 0 8 75 100 200 ATS46 C25N 257 250VA 1 6 0 8 100 125 250 ATS46 C32N 320 250VA 1 6 0 8 125 150 300 ATS46 C41N 410 350VA 1 6 0 8 150 350 ATS46 C48N 480 350VA 1 6 0 8 200 400 ATS46 C59N 590 350VA 16 08 200 250 500 ATS46 C66N 660 350VA 1 6 0 8 250 300 600 ATS46 C79N 790 500VA 3 0 1 5 300 400 800 ATS46 M10N 1000 500VA 3 0 1 5 400 450 900 ATS46 M12N 1200 500VA 3 0 1 5 To select control operators push buttons pilot lamps and selector switches control power transformers and wire management devices control and power terminal strips wire termina
96. rque profile Tn 4 100 a 80 Torque limit Initial torque 10 Y Y 7 Y P4 Acceleration setting t s Figure 26 Acceleration with Torque Limit Current limit starting is used primarily in high horsepower applications of limited system capacity The current limit is adjustable from 150 to 500 of the controller current rating The current limit setting is always active during start up and overrides all other settings When the user defined current limit setting is reached the torque ramp adjusts to prevent excess current draw When starting if the torque is too low due to dry friction stiff mechanism or high inertia the boost function allows the motor to develop increased torque to initiate motor shaft rotation As Figure 27 shows the voltage applied during the boost may be adjusted from 50 to 100 of the motor nominal voltage and is applied for 5 cycles of mains power Th 4 100 T Vn g Boost Following acceleration ramp 50 Vn 100 ms t s Figure 27 Boost Function The ATS46 controller can be set for freewheel stop deceleration ramp or dynamic braking The default setting is freewheel stop which removes all voltage from the motor terminals after a stop command The time the motor takes to coast to rest depends on inertia and resistive torque of the driven load Deceleration ramping uses the same principles of the acceleration ramp providing a gradual deceleration This f
97. s D88 through C48 are Bussmann part numbers Class L fuses require bolt on connections to user supplied power bus work The molded case switches selected require the addition of operator mechanisms to allow operation from the exterior of an enclosure Refer to the latest editions of the Square D product catalogs for operator mechanism information When using a shunt trip relay for SCR fault isolation order a molded case switch with suffix 1021 for addition of shunt trip coil 1998 Square D All Rights Reserved VD0C32S301B Chapter 2 Wiring June 1998 Circuit Diagrams for Circuit Diagrams Contactors 7 10 12 Disconnect 11 KM1 KM2 KM3 Fusible Disconnect Isolation Contactor a us N ee Shorting Contactor Cla SERO Fuse Block 5 Molded ju Switch LC1 D1211G6 LC1 D1211G6 9 N A RK5 20 9080 FB3611R FHL36000M LC1 D1811G6 LC1 D1811G6 9 N A RK5 30 9080 FB3611R FHL36000M LC1 D3211G6 LC1 D3211G6 9 N A RK5 40 9080 FB3621R FHL36000M LC1 D3211G6 LC1 D3211G6 9 N A RK5 45 9080 FB3621R FHL36000M LC1 D4011G6 LC1 D4011G6 9 LC1 D4011G6 RK5 60 9080 FB3621R FHL36000M LC1 D5011G6 LC1 D5011G6 9 LC1 D5011G6 RK5 70 9080 FB3631R FHL36000M LC1 D6511G6 LC1 D6511G6 9 LC1 D6511G6 RK5 90 9080 FB3631R FHL36000M LC1 D8011G6 LC1 D8011G6 9 LC1 D8011G6 RK5 110 6R200A3BE FHL36000M LC1 D8011G6 LC1 D8011G6 9 LC1 D8011G6 RK5 150 6R200A3BE KHL36000M LC1 F150G6 LC1 F150G6 LA9 FF970 LC1 F150G6 RK5 175 6R200A3BE KHL36000M LC1
98. s June 1998 iv 1998 Square D All Rights Reserved VD0C32S301B June 1998 CHAPTER 1 RECEIVING AND INSTALLATION 1998 Square D All Rights Reserved Chapter 1 Receiving and Installation INTRODUCTION 2 gt EA ee Pe A eg 2 Definition Ot Terms EER erc ttt a a eee ED ERR he 2 TECHNICAL CHARACTERISTICS 2 DIMENSIONS AND WEIGHTS 4 HANDLINGTHECONTROLLER 8 SERIALANDMODELNUMBERS 8 INSTALLATIONPRECAUTIONS 9 MOUNTINGPRECAUTIONS 12 Mounting in General Purpose Metal Enclosure 12 Mounting in Dust and Damp proof Metal Enclosure 13 Thermal Considerations for Sizing Enclosures 13 1 Chapter 1 Receiving and Installation Soft Start Application INTRODUCTION Definition of Terms TECHNICAL CHARACTERISTICS VD0C32S301B June 1998 The ALTISTART 46 ATS46 Soft Start offers state of the art acceleration and deceleration control of standard three phase asynchronous induction squirrel cage motors The ATS46 controller uses a new 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 ensu
99. s can be adjusted to provide Class Motor thermal 2 10 10A 15 20 25 or 30 overload protection as defined per ERP protection Level 2 6 oFF to 3H n IEC 947 4 2 The thermal overload protection may be turned only off if external protection is provided Refer to Figure 36 on page 42 and Figure 37 on page 43 for information about trip curves for motor starting Type Abbreviations A Adjustment C Configuration 50 1998 Square D All Rights Reserved VD0C32S301B June 1998 Table 17 Level 3 Parameters Chapter 4 Controller Setup and Operation Adjusting Controller Settings Parameter Type Adjustment Range Preset Description Ars Automatic reset C oFF an oFF Refer to Table 18 on page 57 for automatic reset operation ELP Torque control oFF an an Torque control should be turned off for applications using motors connected in parallel on the same controller or a motor whose power is very low in relation to the rating of the controller ESE Stator loss compensation C 20 to 90 50 L 5 e optimizes the precision of the starting torque for constant torque applications Configuration of AO1 e0 oed Analog output AO1 can be configured to 0 20 mA or 4 20 mA Assignment of LI aFF L IH THE EE Lo JF S Dm ESTE de he The following settings are available for assigning logic input LI OF F not ass
100. section contains spare part information and parts replacement procedures for ATS46 controllers Table 19 ATS46 Replacement Parts Replacement Part Description Model Catalog No Control Module All models VX4 G461 Control Terminal Strips All models VZ3N007 Keypad All models VW3G46101U Thyristor Modules 2 SCR modules D17 VZ3TM2026M16 D22 D32 VZ3TM2055M16 D38 VZ3TM2090M16 D47 D88 VZ3TM2130M16 C11 VZ3TM2160M1601 C14 C25 VZ3TM2250M16 1 SCR module C32 VZ3TM1400M16 2 SCR modules w o firing board C41 C66 VZ3TP2900M16 C79 M10 M12 VZ3TP2M12M16 Firing Board C41 M12 SF1LG220 D17 VX4G46101 D22 VX4G46102 D32 VX4G46103 D38 VX4G46104 D47 VX4G46105 D62 VX4G46106 D75 VX4G46107 D88 VX4G46108 C11 VX4G46109 C14 VX4G46110 Current Measurement Boards C17 VX4G46111 C21 VX4G46112 C25 VX4G46113 C32 VX4G46114 C41 VX4G46115 C48 VX4G46116 C59 VX4G46117 C66 VX4G46118 C79 VX4G46119 M10 VX4G46120 M12 VX4G46121 D17 062 VY1G461401 D75 C14 VY1G461402 Control Transformers C17 C32 VY1G461403 C41 M12 VY1KG461404 D17 D38 VX4G46161 Filter Card D47 C14 VX4G46163 C17 M12 VX4G46162 D75 C14 SZ1XH07 Cooling Fan C17 M12 VZ3V001 Fan Cover D75 C14 VY1G23101 Thermal Switches Heatsink 90 C D75 C14 SY3AT0007 Heatsink 105 C C17 M12 SY3AT0011 Cooling fan 50 C D75 M12 VZ1GF01 1998 Square D All Rights Reserved VD0C32S301B June 1998
101. t has cleared before the motor may be restarted The ATS46 controller provides a three digit LCD display that can be set up to display the controller and motor characteristics as described in Table 12 Table 12 LCD Display Descriptions LCD Display Description Controller Status Displays a ready run or fault status Motor Current Displays the motor current from 0 to 6000 amps Active during acceleration and steady state Motor Load State Displays the motor torque production from 0 to 150 of the nominal motor torque Active Power Displays the active power as a percentage of the motor nominal power Motor Thermal State Displays the thermal state of the motor from 0 to 120 of the motor full load amp setting Motor Power Factor Displays the motor power factor from 0 1 to 1 39 Chapter 3 Application and Protection VD0C32S301B Display of Motor Values June 1998 40 1998 Square D All Rights Reserved VD0C32S301B June 1998 CHAPTER 4 CONTROLLER SETUP AND OPERATION 1998 Square D All Rights Reserved Chapter 4 Controller Setup and Operation FACTORY PRESETS 4 day n w ka aa dee en RD eee a 40 USING THE KEYPAD kure neas ott cte TR do Payee hope y e cert o EN AA 40 Selecting a Menu Level 41 Operating the Pushbuttons 42 ADJUSTING CONTROLLER SETTINGS 4
102. tions indicated on the referenced control circuit configurations refer to the latest editions of the Square D product catalogs Notes 1 26 Motor full load currents through 500 hp 460 V and 250 hp 230 V are taken from UL508 Table 54 2 NFPA 70 Table 430 150 Above 500 hp 460 V and 250 hp 230 V 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 heavy duty applications select the next larger controller size The ambient temperature indicated in the table represents the temperature of the air surrounding the ALTISTART controller 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 starter For operating ambients above 40 C but not exceeding 60 C the rated current le of the starter must be de rated by 1 2 per C 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 The fuses listed in the Table 11 provide Type 1 protection to the starter and auxiliary power equipment when the power source short circuit current capability is less than or equal to the values listed in Appendix A Fuse holders listed are for Class R fuses only Fuse blocks recommended for use with ATS46 model
103. tors are used for U70 through C58 controllers 9 The D Line Contactor is available as a reversing configuration For these applications change the KM1 part number prefix from LC1 to LC2 to order the KM1 and KM2 combination complete with mechanical interlocks 10 The use of transient suppressors across all contactor coils is recommended Refer to the latest editions of the Square D product catalogs for selection of transient suppressors 11 According to the National Electric Code branch circuit overcurrent protection must be provided for each controller Short circuit protective devices recommended in this table are within NEC requirements Refer to Appendix A for maximum protective device ratings 12 Contactors are sized for AC1 duty and coordinated for short circuit withstand capability when using the overcurrent protective device recommended in the appendix 1998 Square D All Rights Reserved 27 Chapter 2 Wiring VD0C32S301B Circuit Diagrams June 1998 28 1998 Square D All Rights Reserved VD0C32S301B June 1998 CHAPTER 3 APPLICATION AND PROTECTION 1998 Square D All Rights Reserved Chapter 3 Application and Protection SOFT STARTAPPLICATION 30 Standard Duty Applications 30 Heavy Duty Applications 30 Reduced Torque xalat aya kalan SoA ee a a hee ad a nekl di RR 30 MODES
104. tput motor thermal alarm configured to indicate motor current is present Logic output compatible with PLC input or LO2 Logic Output Current threshold alarm LED type pilot light Analog output may be scaled for 0 20 mA AO1 Configurable Analog RM via or 4 20 mA output of motor status Output Connect appropriate meter from AO1 to current COM Logic input logic COM output and analog 0 V reference output common Refer to Table 3 on page 3 for electrical characteristics 19 Chapter 2 Wiring Control Connections 20 VD0C32S301B June 1998 2 Wire Control 3 Wire Control RUN STOP RUN STOP START Interlocking Contacts Interlocking Contacts if used if used Figure 15 Interlocking Contact Connection Table 9 J2 Terminal Connections J2 TERMINAL TYPE FUNCTION DESCRIPTION May be configured for fault indication or for control of isolation contactor Normal state of relay is the state with all power removed from the controller or if a fault is detected When configured for fault indication contacts will energize after successful completion of internal diagnostics and will de energize if a fault is detected If configured for control of an isolation contactor relays will energize after a run command is issued and de energize after deceleration is complete or if a fault is detected If using automatic restart the status of the fault relay is dependent on the type of f
105. troller A CAUTION CONTROLLER OVERHEATING Mount the ATS46 controller within 15 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 Degree of protection NEMA Type 1 IP23 To ensure adequate air flow inside the controller follow these guidelines Leave sufficient space around the controller see Figure 7 A2 2 in 50 mm 8 gt 4 in 100 mm Provide ventilation Ensure sufficient ventilation If necessary install a cooling fan with filters A A N N Figure 7 Ventilation and Clearances 1998 Square D All Rights Reserved VD0C32S301B June 1998 Mounting in Dust and Damp proof Metal Enclosure Thermal Considerations for Sizing Enclosures REMOTE MOUNTING KEYPAD 1998 Square D All Rights Reserved Chapter 1 Receiving and Installation Remote Mounting Keypad Degree of protection NEMA Type 12 IP54 Provide a stirring fan to circulate air inside the enclosure and prevent hot spots in the controller This allows
106. ts 51 INTRODUCTION 4 cem e de VR Dee ya ey e RR ERE ERE 54 FaultRelay Setup xi cien em de W a LEER RR SE 54 Fault Displays pel a LES ee Q w RR 54 RESETITINGTHECONTROLLER 54 Fault Definitions IAA yee ds de k m 55 TROUBLESHOOTING FAULTS 56 Phase Fault iy kilk ka sins ek ER nr en ACE ea an ED 56 Frequency Fault i ereere EER ahaa emer e x e x Ren ae yy i 56 Supply Fault with Run Command Present 57 Motor Thermal Fault 57 Starter Thermal Fault sika cece eee tenes 57 Locked Rotor Fault 22 57 Motor Underload Fault 58 Max Starting Time Exceeded 58 External Faull s aid o Leere cede Dede 58 Internal Serial Link Fault 58 Overcurrent Fault issue ud Rue px a duod 59 Internal Failure Fault nsinzasanaazw 59 Phase Inversion Fault ee enne 59 INTRODUCTION ic EE AZ ay met eR adeo moe RC Weeden 25 62 PERSONNEL PROTECTION PRECAUTIONS 6
107. uit do not provide complete isolation from the 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 certain sequencing must be observed with respect to the run signal supplied to the ATS46 controller During starting of the controller closure of the isolation contactor generally should precede or coincide with 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 The circuit diagrams use this feature of the controller as displayed in Figures 21 and 22 External overcurrent protection devices OCPD in the form of fuses or a circuit breaker must be installed on the line side connections of the ATS46 controller The maximum recommended OCPD rating along with the associated controller short circuit withstand rating is listed in Appendix A 1998 Square D All Rights Reserved 9 Chapter 1 Receiving and Installation VD0C32S301B Installation Precautions June 1998 A WARNING OVERCURRENT DEVICES MUST BE PROPERLY COORDINATED OCPD must be installed on the line side of the ATS46 controller
108. up Fault Display RESETTING THE CONTROLLER 56 VD0C32S301B June 1998 The ALTISTART 46 ATS46 controller provides state of the art protection for the motor and controller and provides flexibility and the ability to adapt to normal power disturbances The following describes the diagnostics available on the ALTISTART 46 controller as well as how the controller will respond to the type of fault detected in manual and automatic restart modes Finally conditions which may have caused the fault condition and corrective actions for each fault code are given A DANGER HAZARDOUS VOLTAGE Read and understand these procedures before servicing ATS46 controllers Installation adjustment repair and maintenance of these controllers must be performed by qualified personnel Electrical shock will result in death or serious injury The ATS46 controller provides relay and logic output for fault indication Both fault outputs can be configured to meet application requirements which can then be set up to provide customized fault indication The controller can also be set up for automatic restart Refer to Chapter 3 for details on programming the controller Logic output LO1 is factory preset to indicate a motor thermal pre alarm which may be configured to initiate a correction in the process prior to exceeding the thermal capacity of the motor The LO1 logic output may also be configured to signal that the motor is running Relay output R1 is
109. urves Excessive Cycling Prevention To avoid excessive starting and stopping adjust the time before starting The range of adjustment is between 0 and 999 seconds When using a freewheel stop the ATS46 controller will not accept a new start command during the time after a STOP command is issued and before the motor starts When using controlled deceleration anew START command will not be accepted until the time elapses after the soft stop or InTeleBraking is complete The factory preset of two seconds ensures de magnetization is complete before motor restart End of soft stop STOP or braking tbS tbs Freewheel Stop Controlled Stop Figure 33 Time before starting 36 1998 Square D All Rights Reserved VD0C32S301B June 1998 Stall and Steady State Protection Chapter 3 Application and Protection Motor Protection and Diagnostics During steady state operation the ATS46 controller provides protection from stalling during acceleration and jamming overcurrent or underload conditions e Continuous overcurrent To prevent stalling set the the maximum start time It ranges from 10 to 999 seconds If the time to reach full soeed exceeds the stall time a fault is detected and the start is aborted To protect against jamming after the motor is up to speed the ATS46 controller detects a fault and aborts motor operation when the current exceeds 5 times the motor rated current for more than
110. utput of the controller Internal short circuit Improper sequence of shorting contactor Corrective Action Remove power from controller and check for Damage to power cables and or motor insulation Damage to thyristors Damage to shorting contactor contactor stuck in closed position Fault Code In F Possible Cause Bad internal connection Rating not recognized Corrective Action Remove power from controller and check the internal connections Fault Code P iF Only applicable if Phr is activated Phr is factory pre set to NO Possible Cause Phase rotation of the mains does not match the Phr selection Corrective Action Remove power from the motor and switch two phases of the mains supply 61 Chapter 5 Fault Management VD0C32S301B Troubleshooting Faults June 1998 62 1998 Square D All Rights Reserved VD0C32S301B June 1998 CHAPTER 6 SERVICING THE CONTROLLER 1998 Square D All Rights Reserved Chapter 6 Servicing the Controller INTRODUGTION Sn EA SoA RARE ee ae ke ne 62 PERSONNEL PROTECTION PRECAUTIONS 62 LIST OF TOOLS AND INSTRUMENTS 63 STANDARDS i e e RII tie rt ee YER A ees 63 PARTS REPLAGEMENT Socia p paia ke mare sages posant Ra NDA oe Re 64 CONTROL MODULE REPLACEMENT 65 POWER SECTION REPAIR 54e gerade sed ER ved ea Aly 66 ATS46D17 to C32 Contro
111. ved VD0C32S301B June 1998 DIMENSIONS AND WEIGHTS 1998 Square D All Rights Reserved Chapter 1 Receiving and Installation Dimensions and Weights 6 01 on ye 2 152 5 8 hele 2059 BA Es 215 3 i se f Detail A ee Typical 2 Places Tn Detail A P e I 000000 E Le pt a DA in c ES G 3 dim mm a 1 Removable earth boss supplied with product but not fitted b c d G H weight in mm in mm in mm in mm in mm in mm Ib kg ATS46D17N 6 70 170 12 84 326 5 95 151 9 93 252 5 91 150 8 27 210 9 04 4 10 ATS46D22N 6 70 170 12 84 326 5 95 151 9 93 252 5 91 150 8 27 210 9 04 4 10 ATS46D32N 6 70 170 14 81 376 5 95 151 11 90 302 5 91 150 10 24 260 9 7 4 40 ATS46D38N 6 70 170 14 81 376 5 95 151 11 90 302 5 91 150 10 24 260 9 7 4 40 Figure 1 ATS46D17N to D38N Dimensions gt O ae oos gr See A DetailB slellellelsla 2059 215 ANN MO 8 o DetailB 6 SE Typical 2 Places 8 o N del La oe i ALA am b c G H weight in mm in mm in mm in mm in mm Ib kg ATS46D47N 9 45 240 13 00 330 6 58 167 8 35
112. ver from 460 500 V terminal and connect single phase voltage supply to terminals C and 460 500 V The power circuit adapts automatically to the input line voltage over a range of 208 to 500 V 10 for standard controllers Table 7 Wire Size and Tightening Torque poem D17N D47N C17N C41N C79N D38N C14N C32N C66N M12N POWER CONNECTIONS Max Wre Se NE 2 0 Bus Bar BusBar Bus Bar L1 L2 L3 A1 B1 C1 Tightening Torque ay ir en 15 88 500 500 500 A2 B2 C2 Mounting Screw I WA n a 12 13 12 13 1 2 13 CONTROL POWER CONNECTIONS C Max Wire Size AW 12 12 12 12 12 400 ighteni 460 500 Hohtening TEE fog 10 5 5 2 5 2 5 2 GROUND CONNECTIONS ae M4 M6 M10 M10 M10 Tightening Torque S SS R 15 25 6 238 238 238 12 B l4 Power terminals suitable for use with 75 C rated conductors copper only Power terminals on controllers ATS46D17N through C14N require metric hex wrenches The appropriate size hex wrench is provided with these controllers Requires user supplied lug and fastener Requires user supplied lug 1998 Square D All Rights Reserved VD0C32S301B Chapter 2 Wiring June 1998 Wiring 211 4T2 3 Figure 10 Power Connections ATS46D47N to C14N 7 A1 A2 B1 B2 C1 C2 OIO Ol O jf id
113. wer Transformer Wiring O 1998 Square D All Rights Reserved VD0C32S301B June 1998 POWER SECTION REPAIR ATS46C41N TO M12 CONTROLLERS SCR Power Pole Assembly 1998 Square D All Rights Reserved Chapter 6 Servicing the Controller Replacing the Control Module Some replacement parts on models ATS46C41 to M12N can only be accessed after removing other items in the power section Make a record of the wire connections and the order and location of all components before removing them from the power section The following list contains replaceable items in the power section of the 410 through 1200 A models Control module Keypad SCR power pole assemblies Firing interface board Current measurement board Filter card Control power transformer Fanand thermal switches Refer to Figure 53 to identify the available replacement parts Table 19 on page 66 lists catalog numbers for each item The instructions for replacing the control module control power transformer thermal switches and fan are the same as for the ATS46C17 through C32N controllers described on pages 66 through 70 Fan Assembly Control Power Current Transformer Measurement Board

5 - Schneider Electric

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