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Altistart 48 Installation Guide - Barr

1. 29 8358 88 222882 E S Programmable amp 3 a Programmable 6 Inputs for logic inputs o o g logic outputs S gt PTC probe HEF PP I 7 eee IE TR ERG oO e gt S ly xn jt JO IO JO O IZ je jw x O JO 2S jw e e 3 l2 i I lO lo JO JO IQ i O O rcr jc mcm jc m ic 0o je Jo joa Ja Ja Ja jt JO Jo ja Fault relay Soft starter Motor t t R1F bypass relay powered o 9 N N I I E Ub o Control supply i Motor Motor sia thermal Gwared Motor Elo ATS48 Y 110 230 Vac alarm P dicen Eg Ex A leo NOTE Wire the fault relay in the line contactor power supply sequence in order to open the electrical circuit in the event of a fault trip condition 4 Setparameter ly in the SEt menu see page 41 to the motor nameplate current 5 Apply power to the control terminals CL1 and CL2 Do not apply power to the power terminals yet and do not give a run command The soft starter displays nLP to indicate that it is not powered up 6 The ATS48 soft starter is factory configured for most standard duty applications See Table 1 for the factory preset values If the factory configuration is not suitable for your application refer to Programming on page 37 for information on changing the parameter settings 7 Apply power to terminals 1 L1 3 L2 and 5 L3 The soft starter will display rdY indicating that it is powered up 8 Connect 24 V to the RUN control termi
2. Table 32 Suggested Components for Standard Duty Applications Induction Motor M Class CC Control Fuse Size Rated hp Ries Device Rated Current Power Burden FU4 FUS Fuses Controller 40 C 2 VA 208 V 230 V 460 V 575 V Model 208 230 V 460 575 V A A 5 10 15 ATS48D17Y 17 25 0 25 7 5 15 20 ATS48D22Y 22 25 0 25 7 5 10 20 25 ATS48D32Y 32 25 0 25 10 x 25 30 ATS48D38Y 38 25 0 25 15 30 40 ATS48D47Y 47 25 0 25 15 20 40 50 ATS48D62Y 62 25 0 25 20 25 50 60 ATS48D75Y 75 25 0 25 25 30 60 75 ATS48D88Y 88 25 0 25 30 40 75 100 ATS48C11Y 110 25 0 25 40 50 100 125 ATS48C14Y 145 25 0 25 50 60 125 150 ATS48C17Y 170 25 0 25 60 75 150 200 ATS48C21Y 210 25 0 25 75 100 200 250 ATS48C25Y 250 25 0 25 100 125 250 300 ATS48C32Y 320 25 0 25 125 150 300 350 ATS48C41Y 410 25 0 25 150 m 350 400 ATS48C48Y 480 25 0 25 200 400 500 ATS48C59Y 590 25 0 25 200 250 500 600 ATS48C66Y 660 25 0 25 250 300 600 800 ATS48C79Y 790 25 0 25 350 350 800 1000 ATS48M10Y 1000 25 0 25 400 450 1000 1200 ATS48M12Y 1200 25 0 25 1 Motor full load currents through 500 hp 460 575 V 250 hp 230 V and 200 hp 208 V are taken from the National Electrical Code NEC NFPA 70 2002 or 460 V and 2 4 A hp for 230 V Motors listed are for standard Table 430 150 Above these ratings motor full load currents are calculated based upon 1 2 A hp duty applications For severe duty applications select the next larger controller size The amb
3. 30072 450 61 06 2002 SC as m See J x T SSS SS 4 SC a1 l a a oe im FUA TocoNrno f lt POWER E TRANSFORMER Fus MOTOR j THERMAL SW l B RRR lo o RUN FWD ATS48 per Ll f A RELAY CONTROLLER O Control circuit 4 EE T 1 DETAIL A L RFR TS1 connected for f RESET IF USED 460 V operation i pr ER O 9 Reconnect as 9 E ired for other RELAY RRR ICI odds c voltages E T AT i I E Tan TS 2 For shorting ici din aie RFR We contactor FAULT i eg EE en 9 4 FAULT e ced KO RELAY circuitry A 3 Relay contact al located on ATS48 FR RFR KM2 d FORWARD controller 1 1 o i ol CONTACTOR 4 Located at motor 1 Jumper if switch i TS2 not present 1 A RRR KM1 Set RFR time i o b f PEVERSING PROGRAMMABLE slightly longer than 1 M CONTACTOR ANALOG OUTPUT the expected l i IF USED deceleration time from rated forward END TSe i speed to zero I START UP d R2A R2C SHORTING Speed ee eee ae ne od Lo CONTACTOR 6 Set RRR time i U PILOT RELAY slightly longer than 1 the expected I deceleration time SCA from rated reverse i MT EEE E a E a E EEE REST SHORTING speed to zero I Os CONTACTOR speed i 7 Remove these 1 contacts to inhibit 1 direction reversal without first Bo pa ey ae a eg E age pe wee POWER ON T depressing STOP i push button i FR U lied User supplie amp sd enis ee ee in i Uie n ee m FAUL
4. A WARNING BRANCH CIRCUIT CONDUCTOR HAZARD If system grounding is not adequate to handle ground fault levels which can exceed 1300 of motor full load amps FLA then this device may not protect the branch circuit conductors In this case external ground fault protection must be properly coordinated Recommended solutions include Time delay fuses coordinated to 125 of motor FLA The fuses listed in Appendix B beginning on page 79 are sized to ensure proper coordination and may be used for applications that do not require start times longer than 50 seconds at 300 current limit or 20 seconds at 500 current limit External overload relay For multi motor applications applications in which motor does not match the controller size or applications that use a full voltage bypass scheme an external overload relay can be coordinated to protect conductors from a high impedance ground fault Failure to follow this instruction can result in death or serious injury When wiring ATS48 controllers follow the wiring practices required by national and local electrical codes In addition follow these guidelines e Use metallic conduit for all controller wiring Do not run control and power wiring in the same conduit e Separate metallic conduits carrying power wiring or low level control wiring by at least 3 in 80 mm e Separate non metallic conduits or cable trays used to carry power wiring from metallic conduit carrying
5. 2 Make sure ventilation is effective and the temperature around the controller remains at an acceptable level 3 Remove any dust and debris from the controller if necessary 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming SECTION 7 PROGRAMMING PROGRAMMING AND SETUP Preliminary Recommendations 2002 Schneider Electric All Rights Reserved A WARNING LOSS OF CONTROL The designer of any control scheme must consider the potential failure modes of control paths and for certain critical control functions provide a means to achieve a safe state during and after a path failure Examples of critical control functions are Emergency Stop and Overtravel Stop Separate or redundant control paths must be provided for critical control functions Failure to follow this instruction can result in death serious injury or equipment damage If starting the soft starter from line power limit operations to the duty cycle ratings described on page 31 Use inputs LI1 to LI4 to control the soft starter When changing the factory configuration record your parameter settings in the Factory Settings table beginning on page 69 When first commissioning an ATS48 controller on a 60 Hz system perform a factory parameter reset see FCS
6. 46 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming Table 20 Protection Menu PrO Parameters continued Code Description Setting Range Factory Setting Hr5 Automatic restart On OFF OFF If this function is active and the soft starter locks on a fault the soft starter automatically restarts if the fault has disappeared and the other operating conditions permit the restart A series of automatic attempts are made to restart the soft starter at intervals of 60 s If a restart has not been possible after 6 attempts the procedure is abandoned and the soft starter remains locked until it is switched off then switched on again or reset manually see Fault Management on page 63 The following faults permit this function PHF FrF CLF USF The soft starter fault relay remains activated if this function is active The run command must be maintained This function can only be used in 2 wire control e OFF Function inactive e On Function active rEH 2002 Schneider Electric All Rights Reserved Reset motor thermal state calculated by the soft starter Logis ng e no Function inactive e YES Function active 47 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTAR
7. e 14to 122 F 10 C to 50 C with user provided shorting bypass contactor Maximum relative humidity 95 without condensation or dripping water conforming to IEC 60068 2 3 Maximum ambient pollution Conforms to IEC 60664 1 Pollution Degree 3 Maximum operating altitude 3300 ft 1000 m without derating Above this derate the nominal current by 2 2 for each additional 330 ft 100 m to a maximum of 6600 ft 2000 m Operating position Maximum vertical inclination 10 with respect to the normal mounting position Table 6 Electrical Characteristics Operating category Conforms to IEC 60947 4 2 AC 53a Three phase supply voltage 208 Vac 15 to 690 Vac 10 50 60 Hz Frequency Automatic sensing preset 5 e 60 Hz 56 6 to 63 8 Hz 50 Hz 47 6 to 52 6 Hz Manual selection 20 e 50 Hz 40 to 60 Hz e 60 Hz 48 to 72 Hz Rated current lc 21 device ratings 17 to 1200 A Silicon control rectifiers SCRs 1800 V peak inverse voltage PIV rating Motor power 3 to 1200 hp Motor voltage 208 230 380 460 575 690 Vac Soft starter control circuit supply voltage 110 Vac 15 to 230 Vac 50 60 Hz Maximum control circuit consumption with fans operating E e ATS48D17Y to C17Y 30 W ATS48C21Y to C32Y 50 W e ATS48C41Y to M12Y 80 W Protection 2002 Schneider Electric All Rights Reserved e Integrated thermal Pt
8. v A Alarm Fault Deactivation Activation of motor underload ULL ALA KH dEF OFF l Motor underload threshold as a LUL percent of the nominal torque Lio 5 5 EIC Motor underload time i EUL Excessive starting time fault ELS In se onds v 4 Alarm Fault Deactivation Activation of current overload HL ALA H JEF u OFF a Current overload level as a percent i L Oc of the nominal current poe em aOR Current overload time EOL Acceptance of phase rotation 123 321 PHr Time before restarting Eh5 Ld Parameters First level parameter settings pee Second level parameters depend upon choice of first level parameters To access the parameters see Figure 24 on page 39 30072 450 61 06 2002 The protection parameters can only be modified when the motor is stopped This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 2002 Schneider Electric All Rights Reserved 30072 450 61 06 2002 2002 Schneider Electric All Rights Reserved ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming A CAUTION UNINTENDED OPERATION The factory configuration of a monitoring alarm ALA indicates the presence of a fault but will not directly protect the installation When using parameter ArS ensure that an accidental start will not endanger personnel or equipment in any way Failure to follow this instruction can result in death or serious i
9. ATS48D17Y C66Y Table 9 ATS48D17Y C66Y Dimensions ATSABeee a b c e G H Weight in mm in mm in mm in mm in mm in mm in mm Ib kg D17Y D22Y D32Y D38Y 6 30 160 10 83 275 7 48 190 0 26 6 6 3 94 100 10 24 260 0 28 7 10 8 4 9 D47Y D62Y D75Y D8BY C11Y 7 48 190 11 42 290 9 25 235 0 39 10 5 91 150 10 63 270 0 28 7 18 3 8 3 C14Y C17Y 7 87 200 13 39 340 10 43 265 0 39 10 6 30 160 12 60 320 0 28 7 27 3 12 4 s 12 60 320 14 96 380 10 43 265 0 59 15 9 84 250 13 78 350 0 35 9 40 1 18 2 C41Y CA48Y C59Y C66Y 15 75 400 26 38 670 11 81 300 0 79 20 11 81 300 24 02 610 0 35 9 113 3 51 4 2002 Schneider Electric All Rights Reserved 15 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 3 Technical Data Figure 5 ATS48C79Y M12Y 30072 450 61 06 2002 Table 10 ATS48C79Y M12Y Dimensions a b c e G H o Weight Eben dE 30 31 770 35 04 890 12 40 315 0 79 20 13 78 350 33 46 850 0 35 9 253 6 115 SERIAL AND MODEL NUMBERS 16 The serial and model numbers of the ATS48 controller are on the bar code sticker located on the front right hand side of the device Figure 6
10. e Power supply 24 V 12 V min 30 V max Loz e Maximum current 200 mA per output with an external source Output can be configured as 0 20 mA or 4 20 mA AO1 Programmable analog output e Accuracy 5 of the maximum value maximum impedance 500 Q COM 1 0 common OV Total resistance of probe circuit 750 Q at 25 C PTC1 PTC2 Input for PTC probes e For example three 250 probes in series Connector for RJ 45 Remote keypad display RS 485 MODBUS e PowerSuite e Communication bus 30 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 6 Application and Protection SECTION 6 APPLICATION AND PROTECTION SOFT STARTER APPLICATIONS Standard Duty Applications Severe Duty Applications Reduced Torque 2002 Schneider Electric All Rights Reserved The ATS48 soft starter must be selected for the nominal power of the motor and for the type of application standard or severe duty Standard and severe define the limiting values of the current and the duty cycle characteristics The ATS48 controller is factory preset to start the motor in standard duty applications In standard duty applications the ATS48 soft starter is designed to provide e Starting at 400 of Iy for 23 seconds or 300 of Iy for 46 seconds from a cold state e Starting at 400 of I
11. i SER l PROGRAMMABLE E t POWER ON N O CONTACT 1 LA 7 I I FR Noe ij a E w i 9 FAULT O Control circuit connected for 460 V Koan 1 operation Reconnect as required I 1 for other voltages i Ic Vox 2 For shorting contactor operation a J L NE SEE a ERE E an N 2 a L RUN add SC with associated control PU d wiring 3 Relay contact located on ATS48 controller 4 Located at motor Jumper if switch DETAIL A not present WIRE CONTROLWI AUTO 2 WIRE CONTROL W O AUTO 3 WIRE CONTROL i pirat Aime soney enger than OFF OFF ON rated speed to zero speed The l HAND AUTO B STOP START 1 time delay RCR contact may be Lt 1 I B T omitted if the configuration of the A X i USER i o ojo A o olo o o B f R1 relay is changed to isolating l 1 SUPPLIED OB o B OR i relay mode i L I x T Il E s n User supplied 2002 Schneider Electric All Rights Reserved 75 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Appendix A Recommended Wiring Diagrams Figure 35 AC LINE SUPPLY Reversing with Isolation Contactors 1 L1
12. uen ne eee teet eee cd cree eve Rcs 67 Factory Settings drin tori de piter tert edes an ed oe 69 ES ous etude cce NS demie defe ac ease LL Lene 73 M CIF SER EE a a a cate a at ane tot RIS 77 3 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Table of Contents 06 2002 APPENDIX C OPTIONS AND ACCESSORIES 1 eene nennen nnne nnrtennr trn ennnen rn en nnne erret 79 PowerSuite Advanced Dialogue Solutions ssessss 79 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 1 Quick Start Procedure SECTION 1 QUICK START PROCEDURE A CAUTION HAZARD OF EQUIPMENT DAMAGE Do not operate or install any equipment that appears damaged Failure to follow this instruction can result in injury or equipment damage 1 Before installing or storing the ALTISTART 48 ATS48 soft starter thoroughly inspect it according to the instructions in Receiving and Preliminary Inspection on page 9 a Verify that the soft starter catalog number printed on the label is the same as that on the packing slip and corresponding purchase order b Remove the ATS48 soft starter from its packaging and check that it has not been damaged during transit
13. C for temperatures above 40 C if a shorting bypass contactor is not used 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 4 Mounting Thermal Considerations for Sizing When mounting the ATS48 soft starter in an enclosure use the enclosure Enclosures manufacturers recommendations for proper sizing based on thermal considerations For this it is necessary to sum the power dissipated by each device in the enclosure Table 12 lists the steady state power dissipation for the ATS48 soft starter operating at rated current with and without a shorting bypass contactor Table 12 Watts Loss Information Power Dissipation in Watts Power Dissipation in Watts Catalog Number with Shorting Bypass Without Catalog Number with Shorting Bypass without Contactor Shorting Bypass Contactor Shorting Bypass Contactor Contactor ATS48D17Y 15W 59 W ATS48C21Y 50 W 580 W ATS48D22Y 15W 74W ATS48C25Y 50 W 695 W ATS48D32Y 25 W 104 W ATS48C32Y 50 W 902 W ATS48D38Y 25 W 116 W ATS48C41Y 80 W 1339 W ATS48D47Y 25 W 142 W ATS48C48Y 80 W 1386 W ATS48D62Y 25 W 201 W ATS48C59Y 80 W 1731 W ATS48D75Y 25 W 245 W ATS48C66Y 80 W 1958 W ATS48D88Y 25W 290 W ATS48C79Y 80 W 2537 W ATS48C11Y 25 W 322 W ATS48M10Y 80 W 2865 W ATS48C14Y 25 W 391 W ATS48M12Y 80 W 3497 W ATS4
14. On OFF On e OFF function inactive e On function active In the On position starting and deceleration follow the torque ramp In the OFF position starting and deceleration are controlled by voltage variation Voltage control is recommended for applications which use motors in parallel on one soft starter or a motor whose power is very low in relation to the soft starter rating When tests on smaller motor SSt is active CLP is set to OFF 2002 Schneider Electric All Rights Reserved 49 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming 50 30072 450 61 06 2002 Table 21 Advanced Setting Menu drC Parameters continued Code Description Setting Range Factory Setting LSE Stator loss compensation 0 to 90 50 Parameter active in acceleration phases and deceleration phases if StY is set to d In the event of torque oscillations reduce this parameter gradually until the device is functioning correctly Oscillations are most common if the soft starter is connected in motors with excessive slip Deceleration gain for torque control 10 to 50 40 This parameter can only be accessed if CLP is set to On and if the StY parameter SEt Settings menu is set to d It can be used to eliminate instability during deceleration Adjust the parameter in accor
15. Wiring Figure 15 Power Connections ATS48C79Y to M12Y Dims in mm 18x014 mm t e o CONTROL CONNECTIONS Although all control inputs and outputs of the controller are isolated from the input lines follow these control wiring precautions 2002 Schneider Electric All Rights Reserved Keep control wiring conductor runs short and direct Ensure that the control contacts used with the controller inputs are rated for operation at open circuit voltages of 24 Vdc and closed circuit currents of 10 mAdc The analog output requires twisted cable with a pitch of 1 2 inches Use a cable shield The shield must be terminated to ground at one end Ensure that the coils of all relays and solenoids connected to the output contacts of the controller are equipped with appropriate transient suppressors For proper control wiring route conductors to avoid contact with other voltage potentials in the controller Wire insulation must have the appropriate voltage rating for the voltage present The control terminals are fitted with one way plug in connectors with Maximum wire size 12 AWG 2 5 mm Maximum tightening torque 3 5 Ib in 4 Nem On ATS48C17Y to ATS48M12Y the protective cover must be removed in order to access the control terminals 29 This document provi
16. an ro dz RoR oR OFF ON x 1 I a I l I L2 gt 24V o o MV i o6 o6 i 74 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Appendix A Recommended Wiring Diagrams Figure 34 Nonreversing with Isolation Contactor A _ AC LINE SUPPLY B 2 l Ea l ll 2 i TI FU4 1 ll Tocontro f POWER I T i l TRANSFORMER FUS FU2 FU3 M l II Fg mee Se J 1 l l ATS48 CONTROLLER Lo aad L Ir I veg 0 te i spectet Ti RESET IF USED Loo 120V ri gt T ES Z RCR MOTOR IDE DIM THERMAL SW i SEE i TAN H NICOMMAND i O DETAILA O4 RCR S EAV o 2 A B LZ lone e oui TS1 RCR FAULT RIA R10 a FAULT FR RELAY g 3 ID PROGRAMMABLE ANALOG OUTPUT TS1 IF USED lt O com FR RCR A ISOLATION t M TS ub CONTACTOR I i I TS2 i END i gai i Pad nad jm J SHORTING jr o 1 L o i SCA e CONTACTOR o l i od San PILOT RELAY l ssr E I lt O SCA 4T I l r4 NO SHORTING END og Dp CM CU 4 80 F amp F contactor icu START UR Ju l l e I I I Fe Ls s b
17. circuit breakers selected require the addition of operator mechanisms to allow operation from the exterior of an enclosure Refer to the latest editions of Square D Schneider Electric s full line product catalogs for operator mechanism information When using a shunt trip relay for SCR fault isolation order a disconnect switch with suffix 1021 for addition of shunt trip coil e The D Line contactor is available as a reversing configuration For these applications change the IC1 part number prefix from LC1 to LC2 to order the IC1 and IC2 combination complete with mechanical interlocks 10 Devices rated above 660 A have not been coordinated with circuit breakers You must use a Class L fuse for overcurrent protection with ATS48 controller models C79 M10 and M12 78 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Appendix C Options And Accessories APPENDIX C OPTIONS AND ACCESSORIES Tables 34 36 show the accessories available for ATS48 soft start controllers Table 34 Documentation VVDED302023 MODBUS Protocol User s Manual multilingual Communications Ethernet FIPIO DeviceNet Profibus DP User s Beeps Manual CD ROM version only Table 35 Remote Keypad Display Remote mounting kit for keypad display IP54 e 7 segment remote keypad di
18. faults In this mode relay R1 activates by a RUN command or a preheating command It deactivated at the end of braking or deceleration or when the motor switches to freewheel mode after a STOP command It also deactivates when a fault occurs The motor switches to freewheel mode at this point end of starting relay R2 The end of starting relay R2 is activated when the soft starter is powered up no faults are present and the motor has completed the start up phase It is deactivated in the event of R2 a stop request or a fault It has one normally open contact N O It can be used to bypass the ATS48 soft starter at the end of the starting phase This is not a programmable feature Relay R3 rni e no not assigned e tAl motor thermal alarm See page 33 e ml motor powered 3 e AIL motor current alarm threshold OIL and time tOL of PrO menu exceeded See page 46 e AUL motor underload alarm threshold LUL and time tUL of PrO menu exceeded See page 45 e APC motor PTC probe alarm See PtC on page 46 e AS2 second set of motor parameters activated See LIS on page 52 Analog output OCr e no not assigned e OCr motor current HU e Otr motor torque e OtH motor thermal state e OCO power factor e OPr active power Configuration of the analog output AO 020 420 020 O 4 e 020 0 20 mA signal e 420 4 20 mA signal Scaling of the analog output 50 to 500 200 ASE This parameter allows you to scale the analog output as a percentage
19. if any damage is found notify the carrier and your Schneider Electric representative 2 Install the ATS48 soft starter in accordance with the mounting ventilation and environmental requirements specified under Mounting on page 17 A DANGER HAZARDOUS VOLTAGE Disconnect all power supplying this equipment prior to working on it Failure to follow this instruction will result in death or serious injury 3 With the power removed make the following connections to the ATS48 soft starter a Connect the 115 V or 230 Vac control supply to CL1 and CL2 b Connect the power supply to 1 L1 3 L2 and 5 L3 c Connect the motor to 2 T1 4 T2 and 6 T3 NOTE If a shorting bypass contactor is used connect it between L1 L2 and L3 on the line side supply terminals and A2 B2 and C2 of the ATS48 soft starter Refer to Figure 1 and to the wiring diagrams in Appendix A beginning on page 73 2002 Schneider Electric All Rights Reserved 5 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 1 Quick Start Procedure 06 2002 Figure 1 Power Block Diagram i Soft Starter i A2 l l E l i orm 2 T1 4 T2 6 T3 Motor I I AC Line i 3 L2 4 T2 supply a i A2 B2 C2 ji Soft starter i I C pypass 5 L3 oT 6 T3 l l Figure2 Control Circuit Terminal Configuration
20. low level control wiring by at least 12 in 305 mm e Always cross power and control wiring at right angles The control circuit is completely independent of the power circuit To apply control voltage follow the instructions on the label located on the controller terminal strip Remove the terminal cover label and connect single phase voltage of 110 to 230 Vac supply to terminals CL1 and CL2 The power circuit adapts automatically to the input line voltage and frequency over a range of 208 to 690 V 10 to 1596 for standard controllers 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 5 Wiring POWER CONNECTIONS Table 13 Wire Size and Tightening Torque Terminals ATS48D17Y ATS48D62Y ATS48C14Y ATS48C21Y ATS48C41Y ATS48C79Y D47Y C11Y C17Y C32Y C66Y M12Y Power Input Power Output Bypass Shorting Contactor Max Wire Size 2 2 2 2 Bus Bar Bus Bar a este AWG mm 8 AWG 16 mm 2 0 AWG 50 mm 2 0 AWG 95 mm Bus Bar 240 mm 2x240 mm 4x240 mm A2 B2 C2 BR Torque 26 Ib in 3 Nem 88 Ib in 10 Nem 300 Ib in 34 Nem 300 Ib in 34 Nem 500 Ib in 57 Nem 500 Ib in 57 Nem Ground Connections Max Wire Size 8 AWG 10mm 4 AWG 16 mm Bus Bar 120 mm Bus Bar 120 mm Bus Bar 240 mm Bus Bar AWG mm b nS SAA
21. recommended Refer to the latest editions of Square D Schneider Electric s full line product catalogs for selection of transient suppressors I According to the National Electrical Code branch circuit overcurrent protection must be provided for each controller Short circuit protective devices recommended in this table are within NEC requirements for Type 1 coordination a According to the National Electrical Code branch circuit overcurrent protection must be provided for each controller Short circuit protective devices recommended in this table are within NEC requirements for Type 1 coordination o Reversing contactors for C11 through M12 controllers must be assembled from components Parts quantities for a basic contactor assembly minus the power connection links and terminals are indicated before each part number Refer to the latest editions of Square D Schneider Electric s full line product catalogs for power connector link and terminal kits Reversing contactor interlock units used for the C79 through M12 controllers are designed for vertical interlocking of the individual contactors Horizontally interlocked contactors are used for D17 through C59 controllers NI Fuse holder part number references are for Class J fuses only based on Ferraz Shawmut spring reinforced with box type connectors acceptable for Al Cu wiring Class L fuses require bolt on connections to user supplied power bus work The molded case switches and
22. s 0 s Ol ACC Initial starting torque 0 to 100 of Ty 20 Initial torque setting during the starting phases varies from 0 to 100 of the nominal torque Cn 4 EHU acc Type of stop d b F F Three types of stop are possible e d Soft stopping by control of motor torque The soft starter applies torque to the SEY motor in order to decelerate progressively on the ramp avoiding a rapid stop This type of stop reduces the risk of water hammer on a pump e b INTELE braking stop The soft starter generates braking torque in the motor which will slow the motor down if there is considerable inertia See page 32 e F Freewheel stop The soft starter applies no torque to the motor 2002 Schneider Electric All Rights Reserved 41 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming 42 30072 450 61 06 2002 Table 19 Settings Menu SEt Parameters continued Code Description Setting Range Factory Setting Deceleration ramp time 1to 60s 15s This parameter can only be accessed if StY is set to d Selects the time 1 to 60 s the soft starter will take to reduce the estimated torque to zero during a type d stop This setting determines the gradient of the torque ramp on deceleration This feature is useful in pumping applications to prevent hydraulic shock which may occur if the motor dece
23. setting Invert two line phases or set PHr to no in the Protection menu EEF Internal memory fault Disconnect and reconnect the control supply If the fault persists 2002 Schneider Electric All Rights Reserved contact Schneider Electric product support 63 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 8 Fault Management 06 2002 RESETTABLE FAULTS WHEN When a resettable fault appears the soft starter locks and the motor switches CAUSES DISAPPEAR to freewheel mode The following are signals that a resettable fault has occurred Relay R2 opens e If relay R1 is configured as an isolating relay it opens e The fault code flashes on the display as long as the fault is present The last 5 faults are stored and viewable with the PowerSuite software workshop Do the following before restarting the soft starter e Remove the cause of the fault see Table 27 e n2 wire control maintain the run command on the RUN input n 3 wire control initiate a new run command rising edge on the RUN input Table 27 Resettable Fault Correction Fault Displayed Probable Cause Corrective Action e Revert to the factory setting in the drive menu drC CFF Invalid configuration on power up e Reconfigure the soft starter Invalid configuration Check the initial configuration CFI The configuration loa
24. to all applicable code requirements with respect to grounding all equipment See Figures 11 15 on pages 25 29 for grounding points Many parts in this controller including printed wiring boards operate at line voltage DO NOT TOUCH Use only electrically insulated tools while making adjustments DO NOT touch unshielded components or terminal strip screw connections with voltage present Before installing or servicing the controller Disconnect all power Place a DO NOT TURN ON label on the controller disconnect Lock the disconnect in the open position Install all covers before applying power or starting and stopping the controller 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 21 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 5 Wiring 06 2002 A DANGER HAZARDOUS VOLTAGE The solid state switches of the ATS48 controller s power circuit do not provide complete isolation from the AC line Due to leakage currents through the solid state switches hazardous voltages can be present on the controller load side power circuit whenever power is applied to the line side of the controller e Disconnect all power before servicing the controller or motor Electrical shock
25. will result in death or serious injury e When using an isolation contactor the contactor must close before or at the same time as the application of the controller run command If line power is not detected at the L1 L2 and L3 terminals of the controller within 500 ms of this run command a Phase Failure fault will occur e External overcurrent protection devices OCPD either fuses or a circuit breaker must be installed on the line side connections of the ATS48 controller The maximum recommended OCPD rating along with the associated controller short circuit withstand rating is listed in Table 8 on page 14 A WARNING OVERCURRENT DEVICES MUST BE PROPERLY COORDINATED An OCPD must be installed on the line side of the ATS48 controller to achieve published short circuit withstand ratings Do not exceed the maximum OCPD ratings shown in Table 8 on page 14 Do not connect the controller to a power feeder whose short circuit capacity exceeds the controller short circuit withstand rating shown in Table 8 on page 14 Failure to follow this instruction can result in death or serious injury e Power factor correction capacitors should not be connected to a motor controlled by an ATS48 controller If power factor correction is required the capacitors must be located on the line side of the controller A separate contactor should be used to switch the capacitors off when the motor is off or during acceleratio
26. 0 D DCF 63 dE2 56 dEC 42 EbA 43 Ed2 56 EdC 42 EEF 63 EtA 59 EtF 66 F factory settings 69 faults auto reset 65 manual reset 66 non reset 63 resettable 64 FCS 50 FOr 57 FrC 50 freewheel stop 41 FrF 65 fuses 14 77 78 2002 Schneider Electric All Rights Reserved ALTISTART 48 Y Range Soft Start Controllers IL2 55 ILt 41 In 41 In2 55 InF 63 INTELE braking stop 32 41 IPr 52 isolation contactor 23 78 L LAP 59 LCr 59 LFt 59 LI3 52 Ll4 52 LIA 52 LIC 52 LIE 52 LIH 52 LI 52 LIL 52 Lir 52 LIS 52 Lit 52 LO1 53 LO2 53 LOC 46 LPr 59 LrF 66 LSC 50 Ltr 59 LUL 45 M menus access to 39 advanced setting drC 48 communication COP 57 VO IO 51 parameter displayed SUP 58 protection PrO 44 second motor parameters St2 54 settings SEt 40 O O4 53 OCO 53 OCr 53 OIL 46 OLC 66 OLF 66 OPr 53 OtF 66 OtH 53 Otr 53 This document provided by Barr Thorp Electric Co Inc 800 473 9123 Index P parameter access 39 PCt 58 PHE 60 PHF 65 PHL 46 PHr 46 PIF 63 PtC 46 R ri 53 riF 53 ril 53 r3 53 reversing contactor 78 ml 53 rn 59 rPr 50 rH 47 S setting factory 69 shorting contactor 78 shunt trip coil 23 73 SLF 66 soft stopping 41 SSt 49 starter status 40 stop freewheel 41 INTELE braking soft 41 StY 41 T tAl 53 tbr 57 tbS 46 tHP 45 tHr 59 tl2 56 tiG 50 t2 56 tLl 49 tLP 58 tLS 45 tOL 46 tPr 52 tqgO 41 tq2 55 tUL 4
27. 0 to 999 555 555 1000 to 9990 5 55 5550 Max scale 99900 005 5 1 to 999 055 55 550 550 1000 to 9990 5 55 5550 10000 to 99900 55 5 55500 38 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 7 Programming MENUS Menus are accessible in the order shown in Figure 23 Figure 23 Accessing Menus Display of soft starter status see Table 18 on page 40 for codes Ep GEE T Settings oo f D fp o rean _ _ _ e ue Advanced settings j i SYS T Communication Sp Selection of the parameter Z displayed and the locking code TMN 1 Menu St2 is only available if the second set of motor parameters function is configured See the I O menu on page 51 a see 2nd motor parameters 1 j Q To store the displayed choice press ENT The display flashes when a value is stored Navigate through the menus depending upon the button pressed as shown in Figure 24 Figure 24 Accessing Parameters Parameter Value or assignment Menu SEE ACC 9 gie Browsing within Lo the menus EU Next parameter 2002 Schneider Electric All Rights Reserved 39 This doc
28. 2 450 61 06 2002 MOTOR PROTECTION AND DIAGNOSTICS Thermal Overload Protection 2002 Schneider Electric All Rights Reserved ALTISTART 48 Y Range Soft Start Controllers Section 6 Application and Protection where t sec Calculated value must be equal to or less than 40 WK Connected motor load inertia Ib ft Arpm Change in rpm or synchronous speed Tfr Full Load Torque lb ft The ATS48 controller provides state of the art motor protection On all controllers the motor protection features are available even if a shorting bypass contactor is used to bypass the SCRs after the motor is up to speed To assist with troubleshooting the 3 digit LCD displays fault status codes The controller memory registers and maintains the previous 5 faults even following power loss The ATS48 controller is a UL Listed motor controller with integrated motor and controller thermal protection The motor and controller temperature are continuously calculated based on the controller nominal current and the current that is actually drawn An electronic circuit which stores the thermal state of the motor even if the supply power is disconnected simulates the cooling curve Overload of any kind over any duration can cause the motor temperature to rise As Figure 19 shows the ATS48 controller creates a digital model of the motor temperature based on two thermal images The first T1 represents the level of temperature rise corresponding to i
29. 23 or no no If the line phases are not in the order configured the soft starter locks and displays the fault PIF This parameter tells the soft starter the line phase order e 321 reverse L3 L2 L1 e 123 forward L1 L2 L3 e no not monitoring PHr Time before starting 0 to 999 s 2s This parameter avoids starts in quick succession which may overheat the motor The time delay starts when the motor changes to freewheel mode bas In 2 wire control the motor is restarted after the time delay if the RUN command input is still activated In 3 wire control the motor is restarted after the time delay if anew RUN command is sent rising edge The soft starter displays E b 5 during the time delay Phase loss threshold 5 to 10 1096 PHL If the motor current falls below this threshold in one phase for 0 5 s or in all three phases for 0 2 s the soft starter locks and displays the fault PHF Can be set at between 5 and 10 of the lc soft starter rating Activation of motor monitoring by PTC probes arr The PTC probes on the motor must be connected to the correct analog input This protection is independent of the calculated thermal protection tHP parameter Both PEL types of protection can be used simultaneously ALA an alarm is activated internal bit and assignable logic output e dEF the soft starter is locked and the OtF fault is displayed e OFF no protection
30. 30072 450 87 04 2003 Raleigh NC USA Errata ERRATA for bulletin 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers Installation Guide Retain for future use CORRECTIONS If you have the first printing of installation guide 30072 450 61 dated 06 2002 make the following changes to the document The printing date is in the header of most pages In the following bullets boldface indicates the correct word or phrase e Page 52 Table 22 under Logic inputs Under LIL force to local control mode this should read If a serial link is used and this function is set the soft starter changes from link mode e Page 53 Table 22 under End of Starting Relay R2 R2 should be shown in the LCD display font e Page 59 Table 25 under Operating Time The sentence in the third paragraph should read The hour counter can be reset in the link mode e Page 59 Table 25 under Display of the current state The last bullet should read nSt force to freewheel stop by a logic input or the serial link Page 74 in Figure 33 Nonreversing with Shunt Trip Fault Isolation An additional interposing relay FR should be added per Figure 2 e Page 75 in Figure 34 Non Reversing with Isolation Contactor The FR normally closed contact shown in the isolation contactor control circuit should be shown as a normally ope
31. 5 32 41 ULF 66 ULn 50 USF 65 81 www barr thorp com ALTISTART 48 Soft Start Controllers e SSS O a SSS O e to O n TE un Y ON N Inr Sco o o O e 0 S Square D Company Electrical equipment should be serviced only by qualified personnel No responsibility 8001 Highway 64 East is assumed by Schneider Electric for any consequences arising out of the use of this Knightdale NC 27545 USA material This document is not intended as an instruction manual for untrained 1 888 SquareD 1 888 778 2733 persons Www SquamsD com 30072 450 61 06 2002 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com
32. 500 A 1 15 is 1150 A A or kA Operating time in hours since the last reset In hours up to 999 hrs examples 001 is 1 hr and 111 is 111 hrs In kilo hours from 1000 to 65535 examples 1 11 is 1110 hrs and 11 1 is 11100 hrs Above 65535 hrs 65 5 the display resets to zero Operating time is counted when the motor is not stopped i e when the thyristors are fired heating acceleration steady state deceleration braking and in continuous bypass operation The hour counter can be reset in line mode using the control word or via the keypad display with the motor stopped When the power is removed from the 115 Vac control power supply the hour counter is saved in the EEPROM h or kh Active power varies from 0 to 255 100 corresponds to the power at nominal current and at full voltage 96 Motor torque varies from 0 to 255 100 corresponds to the nominal torque 96 LAP Active power in kW This parameter requires configuration of the exact value of the line voltage ULn in the drC menu ELA Display of the current state e nLP soft starter without run command and power not supplied e rdY soft starter without run command and power supplied e tbS starting time delay not elapsed e ACC acceleration in progress e dEC deceleration in progress e rUn steady state operation e brL braking in progress e CLI soft starter in current limiting mode e nSt force to freewheel stop by serial l
33. 800 630 1000 900 1000 1000 ATS48M10Y 400 450 710 1000 800 1200 1200 1200 ATS48M12Y 2002 Schneider Electric All Rights Reserved 11 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 3 Technical Data 06 2002 Table 4 Severe Duty Application 208 to 690 V Supply 10 to 159 6 50 or 60 Hz Max Current Rating hp e hp e kW hp kW hp kW r for Class 10 Thermal Ic Ratin Catalog Number 208V 230V 440V 460V 500V 575V 690V cL rating 3 Overload Protection 5 5 7 5 7 5 10 11 12 17 ATS48D17Y 7 5 10 9 15 15 17 22 ATS48D22Y 7 5 11 15 11 20 18 5 22 32 ATS48D32Y 75 10 15 20 18 5 25 22 32 38 ATS48D38Y 10 18 5 25 22 30 30 38 47 ATS48D47Y 15 22 30 30 40 37 47 62 ATS48D62Y 15 20 30 40 37 50 45 62 75 ATS48D75Y 20 25 37 50 45 60 55 75 88 ATS48D88Y 25 30 45 60 55 75 75 88 110 ATS48C11Y 30 40 55 75 75 100 90 110 140 ATS48C14Y 40 50 75 100 90 125 110 140 170 ATS48C17Y 50 60 90 125 110 150 160 170 210 ATS48C21Y 60 75 110 150 132 200 200 210 250 ATS48C25Y 75 100 132 200 160 250 250 250 320 ATS48C32Y 100 125 160 250 220 300 315 320 410 ATS48C41Y 125 150 220 300 250 350 400 410 480 ATS48C48Y 150 250 350 315 400 500 480 590 ATS48C59Y 200 355 400 400 500 560 590 660 ATS48C66Y 200 250 400 500 600 630 660 790 ATS48C79
34. 8C17Y 25 W 479 W The total dissipated Watts loss is provided strictly for sizing the environmental HVAC cooling requirements based upon nominal current operating conditions The control power circuit consumption is 25 W REMOTE KEYPAD DISPLAY The VW3G48101 remote keypad display can be mounted on the door of a IF USED wall mounted or floor standing enclosure The remote keypad display kit includes a seal for IP65 protection and a 9 82 ft 3 m cable with connectors Communication is via the RJ 45 MODBUS connection on the starter see Figure 10 The remote keypad display has the same signaling display and configuration buttons as the controllers integral keypad display A switch to lock access to the parameters is located at the rear of the keypad display Figure 9 Remote Keypad Display Front and Rear Views Q Connector E 2 3 characters O O access switch 2002 Schneider Electric All Rights Reserved 19 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 4 Mounting 06 2002 The access switch on the remote keypad display is used as follows Locked Position Only monitoring parameters can be accessed When the starter is running it is not possible to select a different parameter to be displayed e Partial Locked Position Limited access to the SEt PrO and SUP menu parameters
35. 8G7 D32Y LC1D25G7 LC1D25G7 9 LC1D25G7 D38Y LC1D32G7 LC1D32G7 9 LC1D32G7 D47Y LC1D32G7 LC1D32G7 9 LC1D32G7 D62Y LC1D40G7 LC1D40G7 9 LC1D40G7 D75Y LC1D80G7 LC1D80G7 9 LC1D80G7 D88Y LC1D80G7 LC1D80G7 9 LC1D80G7 C11Y LC1D80G7 LC1D80G7 9 LC1D80G7 C14Y LC1D115G7 LC1D115G7 9 LC1D115G7 C17Y LC1D115G7 LC1D115G7 9 LC1D115G7 C21Y LC1D150G7 LC1D150G7 LA9 FG970 LC1D150G7 C25Y LC1F185G6 LC1F185G6 LA9 FJ970 LC1F185G6 C32Y LC1F330G7 LC1F330G7 LA9 FJ970 LC1F330G7 C41Y LC1F330G7 LC1F330G7 LA9 FJ970 LC1F330G7 C48Y LC1F400F7 LC1F400F7 LA9 FJ970 LC1F400F7 C59Y LC1F500F7 LC1F500F7 LA9 FJ970 LC1F500F7 C66Y LC1F630F7 LC1F630F7 LA9 FJ970 LC1F630F7 C79Y LC1F630F7 LC1F630F7 LA9 FL970 LC1F630F7 M10Y LC1F630F7 LC1F630F7 LA9 FL970 LC1F630F7 M12Y LC1F780F7 LC1F780F7 LA9 FX970 LC1F780F7 N w o o All coils are selected for 120 V 60 Hz operation Refer to the Square D Digest for additional coil voltages or auxiliary contact configurations One block may be added to each contactor Power terminals are not included with LC1F contactors Refer to the latest editions of Square D Schneider Electric s full line product catalogs for additional ordering information The use of transient suppressors across all contactor coils is recommended Refer to the latest editions of Square D Schneider Electric s full line product catalogs for selection of transient suppressors Reversing contactors for C11 through M12 controllers must be assembled from components Parts quantiti
36. Bus Bar T Bus Rari 2x240 mm GND 1 Power terminals are suitable for use with 75 C rated conductors copper only Tightening Torque Ib in Nem Requires user supplied lug 15 Ib in 1 7 Nem 2002 Schneider Electric All Rights Reserved 26 Ib in 3 Nem Figure 11 238 Ib in 27 Nem 238 Ib in 27 Nem 238 Ib in 27 Nem Power Connections ATS48D17Y to C11Y 3 L2 5 L3 238 Ib in 27 Nem ooooooo mooooooooooo A2 B2 C2 EH 2 T1 4 T2 6 13 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 25 26 ALTISTART 48 Y Range Soft Start Controllers Section 5 Wiring 30072 450 61 06 2002 Figure 12 Power Connections ATS48C14Y to C17Y 0 2 07 t 0 8 Ea 18 M6 20 0 4 5 53 ES 0 08 9x99 mm10 IF 159 y 2 4 muni ay ojs i G i i i N 1 L1 3 L2 5 L3 0 04 Oo O GI o E EBH O O o T o 0 6 L L L J 14 olm Jo lane eis y I i Nae ED A2 i M6 B2 2 as oos Dims in 162 a540 24 ae mm motor 38 62 62 2002 Schneider Electric All
37. E Voltage boost level OFF 50 to 100 of mains voltage SE Tests on a small motor OFF On OFF ELP Torque control type of control On On OFF o o ESE Stator loss compensation 50 0 to 90 2 gt o 0 z g E IL Deceleration gain for torque control 40 10 to 50 e S csc Activation of cascade function OFF On OFF o lt LL n Line voltage 690 180 to 790 V Fr Line frequency AUt 50 60 AUt Pr Reset kWh or the operating time no No APH trE FOS Return to factory settings no No YES 70 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 8 Fault Management 30072 450 61 06 2002 FACTORY SETTINGS continued Code Designation Factory Setting Customer Setting Parameter Range and Units Logic inputs LIA LIL No not assigned LIA forced free wheel LIE external fault LIH not implemented LIL force to local control mode LII inhibition of faults Lit reset motor thermal fault LIC activate cascade function LIR fault reset LIM second configuration Preheating level 0 0 to 100 Time delay before preheating 5mn 0 to 999 minutes Logic outputs tAI rni No not assigned tAl motor thermal alarm rnl motor powered AIL motor current alarm AUL motor underload alarm APC motor PTC sensor alarm AS2 second configuration active Relay
38. H and LII to take effect ENT must be pressed for 10 s confirmed by flashing display These parameters cannot be modified via the remote keypad display 52 Code 30072 450 61 06 2002 Table 22 I O Menu IO Parameters Description Setting Range Factory Setting n LIA ogic inputs idi LIL The selected function is active if the input is powered up e no not assigned e LIA forced freewheel stop It forces the configuration of a freewheel type stop but does not control the stop as soon as a STOP command is received This selection does not appear if the CSC parameter in the drC menu is set to On LIE external fault This enables the soft starter to detect an external user fault level pressure etc L I3 The motor comes to a freewheel stop and the soft starter displays EtF L 14 Je LIL force to local control mode If a serial link is used and this function is set the soft starter changes from line mode control via serial link to local mode control via keypad displays e Lit reset motor thermal fault e LIC activation of the cascade function This function disables motor thermal protection and requires that relay R1 be configured as an isolating relay It can be used to start and decelerate several identical motors one after the other with a single soft starter Lir reset faults which can be reset e LIS activation of second set of motor parameters This function allow
39. HL36000M FAL36090 D75Y LC1D80 LC1D80 a LC1D80 J 100 61038J FHL36000M FAL36100 D88Y LC1D80 LC1D80 9 LC1D80 J 120 62003J KHL36000M KAL36110 C11Y LC1D115 LC1D115 9 LC1D115 J 150 62003J KHL36000M KAL36150 C14Y LC1D150 LC1D150 9 LC1D150 J 200 62003J KHL36000M KAL36200 C17Y LC1F185 LC1F185 LA9FF970 LC1F185 J 225 64033J LHL36000M LAL36225 C21Y LC1F265 LC1F265 LA9FG970 LC1F265 J 300 64033J LHL36000M LAL36250 C25Y LC1F265 LC1F265 LA9FJ970 LC1F265 J 350 64033J LHL36000M LAL36350 C32Y LC1F400 LC1F400 LA9FJ970 LC1F400 J 400 64033J LHL36000M LAL36400 C41Y LC1F400 LC1F400 LA9FJ970 LC1F400 J 500 6633J MHL36000M MAL36500 C48Y LC1F500 LC1F500 LA9FJ970 LC1F500 J 600 6633J MHL360006M MAL36600 C59Y LC1F630 LC1F630 LA9FJ970 LC1F630 L 700 7 MHL360008M MAL36800 C66Y LC1F800 LC1F800 LA9FJ970 LC1F800 L 900 d MHL360008M MAL36900 C79Y LC1BL33 LC1BL33 LA9FL970 LC1BL33 L 1100 T MHL36000M i M10Y LC1BL33 LC1BL33 LA9FL970 LC1BL33 L 1350 7 MHL36000M a0 M12Y LC1BP33 LC1BP33 LA9FX970 LC1BP33 L 1600 T NCL3600012M 19 All coils are selected for 120 V 60 Hz operation Refer to the Square D Digest for additional coil voltages or auxiliary contact configurations One block may be added to each contactor N Power terminals are not included with LC1 F contactors Refer to the latest editions of Square D Schneider Electric s full line product catalogs for additional ordering information The use of transient suppressors across all contactor coils is
40. L POWER 5 TRANSFORMER FUS E E Ln Ue y py lt T d Fe T SoS ee 21 l RUN BIEN Exec S D cer I ce c9 O ic _ n RESET IF USED a ie a at o O 120V E SEE FU1 y Fus FUS DETAILE FAULT e piu R10 ae TAP 0000 0 0 0000000000 7 uae RELAY TS1 m CB SHUNT M SE ME P TRIP COIL 2 SEC 2 i ois x l p a iere RUN PROGRAMMABLE 4 MEO ANALOG OUTPUT worn S i ioe IF USED lt Q COM 00 17D THERMAL SW 1 SEE i oy RUN COMMAND O O r9 0 l O DETALA RCR Reay l cT aim e MEC EE l 1 C l i ee 1 i kesse etg T3 h d EN i Sele era i LE i END RT 1 START UP A i ey ee Y x SHORTING deccncce m2lce 2 Ac2 5 ot SCA L e CONTACTOR RIC a j lt 0 1 Lo 2 1 d PILOT RELAY l i Sa I z8 rF q SCA jo i SHORTING eee red DEI eee EN ROO S Ld S iic t i SO CONTACTOR Q i I S I 1 ee I I I z389 b dg 1 S a i yt i 4 p L POWERON MS i ON 5 x DETAIL A NEC CC 7 EE e c o l 2 WIRE CONTROL W AUTO 2 WIRE CONTROL W O AUTO 3 WIRE CONTROL i OFF ON j i HAND AUTO 7 ur STOP START l 2 ie T B I i 1 o RX o o olo o A T o o B i T 1 USER OR A zo B OR l l 1 1 SUPPLIED i 3 l H Lp m l D D 1 I l DETAIL B E eet eel ope STOP E STOP i I t gt RUN
41. LINK FAULT LI OHF STARTER THERMAL FAULT LI OCF ovERCURRENT LI FRF LINE FREQUENCY OUT OF TOLERANCE L ETF EXTERNAL FAULT LI OTF MOTOR THERMAL FAULT VIA PTC PROBES L PIF PHASE INVERSION LI USF POWER SUPPLY LI STF EXCESSIVE STARTING TIME LI ULF motor UNDERLOAD LI EEF INTERNAL MEMORY LI CLF CONTROL LINE FAILURE CL1 CL2 LI OLC CURRENT OVERLOAD LI LRF LOCKED ROTOR IN STEADY STATE RESETTABLE FAULTS WHEN CAUSES DISAPPEAR L CFF INVALID CONFIGURATION POWER UP L CFI INVALID CONFIGURATION COMM DETAILED DESCRIPTION OF PROBLEM ATTACH WIRING DIAGRAM SCHEMATICS IF APPLICABLE 06 2002 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 8 Fault Management Code Designation Factory Setting Customer Setting Parameter Range and Units Depends upon starter In Current setting rating 0 5 to 1 3 lg A IL Current limit 400 150 to 500 of In ACC Acceleration ramp time 15 1to60s Zo 90 Initial starting torque 20 0 to 100 of Ty o o lt o d deceleration n Oo 5H Type of stop F free wheel b braked F free wheel dEEL Deceleration ramp time 15 1to60s EdE Final deceleration torque 20 0 to 100 of estimated tor
42. O Assignment of logic output LO2 POS e 4 OG Fault relay Isolation relay Assignment of relay RI P L J E et Assignment of relay R F3 PT j i Not assigned no i ji Thermal alarm motor 1 4 T Motor powered Can be Qo selected Motor current alarm A IL i I Motor underload alarm A UL T PTC probe alarm APE T Second set of motor parameters activated a 2 Assignment of analog output AO gg ONO Hy Not assigned Configuration of the analog outpu 5 4 Oz Motor current T Scaling of the analog output OHO t E Motor torque Can be E Parameters UtH Motor thermal state selected First level parameter settings mes Burg Power factor i 4 Second level parameters depend upon choice of f first level parameters 5 a Active power Typically locked out features 2002 Schneider Electric All Rights Reserved To access the parameters see Figure 24 on page 39 NOTE Logic input RUN logic input STOP and soft starter shorting bypass contactor control R2 cannot be assigned The I O parameters can only be modified when the motor is stopped 51 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming NOTE Shading indicates a typically locked function To unlock the function see LIS LI4 Logic inputs In order for functions LI
43. ONTENTS SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 APPENDIX A APPENDIX B QUICK START PROCEDURE RECEIVING AND HANDLING TECHNICAL DATA MOUNTING WIRING APPLICATION AND PROTECTION PROGRAMMING FAULT MANAGEMENT RECOMMENDED WIRING DIAGRAMS RECOMMENDED COMPONENT LISTS 2002 Schneider Electric All Rights Reserved ALTISTART 48 Y Range Soft Start Controllers Table of Contents T EE 5 IntrOduction cp 9 RE pte obj e 9 Handling the Controller sse 10 Technical Characteristics sesssssseseeeeeeneneenene 11 Sp cifications rice EE EEUU TEE 12 Dimensions and Weights sseeee mee 15 Serial and Model Numbers sss 16 Mounting Precautions eeeeessesessseeeeeeenne a a nnne nne 17 Mounting in a General Purpose Metal Enclosure 18 Soft Starter Ventilation esses 18 Mounting in a Dust and Damp Proof Metal Enclosure 18 Thermal Considerations for Sizing Enclosures 19 Remote Keypad Display if used smn 19 Installation Precautions senm eme 21 General Wiring Practices ssesssesssesseeeeeeeneeeneen enne 24 Adaptation to Line Input ssie iiidi
44. Or 8 bits no parity 1 stop bit 8nl This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 1 Quick Start Procedure 06 2002 8 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 2 Receiving and Handling SECTION 2 RECEIVING AND HANDLING INTRODUCTION Terminology REVISION LEVEL RECEIVING AND PRELIMINARY INSPECTION 2002 Schneider Electric All Rights Reserved The ALTISTART 48 ATS48 soft starter offers state of the art acceleration and deceleration control of standard three phase asynchronous induction squirrel cage motors The ATS48 controller uses a patented technology to control the motor performance based on the motor torque rather than simple voltage or current based control Advanced control algorithms are incorporated to ensure smooth rotation throughout the starting ramp without mechanical instability at the end of starting A microprocessor continuously monitors the motor and controller performance to provide maximum protection of the controller motor and driven machinery A variety of starting and stopping modes are standard A digital keypad display provides accurate controller setup and continuous motor performance display The ATS48 contro
45. R1 nF R1F fault Ril isolation relay 10 Menu Management of Inputs Outputs Relay R3 rl No not assigned tAl motor thermal alarm rnl motor powered AIL motor current alarm AUL motor underload alarm APC motor PTC sensor alarm AS2 second configuration active HU Analog output OCr No not assigned Ocr motor current Otr motor torque OtH motor thermal state OCO power factor OPr active power Configuration of the analog output AO 020 020 0 20 mA 420 4 20 mA Scaling of the analog output 200 50 to 500 2002 Schneider Electric All Rights Reserved 71 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 8 Fault Management FACTORY SETTINGS continued 30072 450 61 06 2002 Code Designation Factory Setting Customer Setting Parameter Range and Units Ing Nominal motor current Depends upon starter 0 5 1 3 lg A rating G o n o IL2 Current limit 400 id 700 of In limited to 500 of cL 2 g ALe Acceleration ramp time 15 1 60 s o SE T S Egg Initial starting torque 20 0 100 of Ty zu N d a 2 dEg Deceleration ramp time 15 1to60s v EN Threshold for changing to freewheel stop 20 0 to 100 of estimated torque mode at end of deceleration EE Maximum torque limit OFF 10 to 200 E le Deceleration gain for
46. Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 5 Wiring Figure 13 Power Connections ATS48C21Y to C32Y 02 54 5 136 5 O X 02 02 5 5 4 m 77 136 5 rei Dims in N 196 5 mm motor 2002 Schneider Electric All Rights Reserved 2 6 66 0 8 9x012 mm Mi 20 0 6 35 as 15 j A Y T A o o i i 1 1 3 2 5 L3 0 08 o o o gt B68 0000 Nol o e oj 0 7 18 O 4 T2 a 6 73 i JL ry ce 0 08 2 3 5 90 27 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 5 Wiring 06 2002 Figure 14 Power Connections ATS48C41Y to C66Y 9x14 mm 3 O o2 65 02 9 8 5 165 2 n 5 i 216 Dims in motor mm 28 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 5
47. Serial Number and Model Numbers Serial Number C 299000000092 ATS48D75Y Model Number 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 4 Mounting SECTION 4 MOUNTING MOUNTING PRECAUTIONS Follow these precautions when mounting the ATS48 controller e Controllers are open devices and must be installed in suitable enclosures or controlled access areas The environment around the controller must meet Pollution Degree 3 requirements as defined in NEMA ICS1 1 or IEC 60664 1 A DANGER HAZARDOUS VOLTAGE ATS48 controllers are open devices and must be mounted in a suitable enclosure Electrical shock will result in death or serious injury e When the installation surface is not even put a spacer behind the controller mounting pads to eliminate gaps Fastening the controller exterior to an uneven surface may damage the controller e When installing the controller in an enclosure cover the device to prevent metallic debris from falling into the controller e The ATS48 controller generates heat and must be properly ventilated Refer to Thermal Considerations for Sizing Enclosures on page 19 to determine power dissipated e When several controllers are installed in a control panel arrange them in a row Do not stack controllers Heat generat
48. T 48 Y Range Soft Start Controllers Section 7 Programming 48 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Figure 27 Advanced Setting Menu drC 30072 450 61 06 2002 Torque limit as a percentage of the nominal torque Voltage boost level Tests on small motor Torque control Stator loss compensation Deceleration gain Activation of the cascade function Line voltage to calculate power in kW Line frequency Reset kWh or the operating time Return to factory settings WII LS 7 e 7 e o e e le z e aint o m JHO LL n e n 4 Qm EES t LL Parameters in menu The Advanced setting parameters can only be modified when the motor is stopped 2002 Schneider Electric All Rights Reserved 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming A CAUTION NO BRAKING AND LIMITED STOPPING With parameter dLt only freewheel type stopping is possible Cascading is not possible Preheating is not possible This limitation can result in injury Table 21 Advanced Setting Menu drC Parameters Code EL I Description Setting Range Factory Setting Torque limit 10 to 200 or OFF OFF Use this parameter to limit the torque reference to avoid regenerative behavior in applications with high inertia It can be used for constant torque sta
49. T PP 1 I l Ici n D aras un o ses ly Dc I AD C NE eg in a s URN A Lid aaa RUE S Ra A RUN FORWARD PROGRAMMABLE nr N O CONTACT i Ic2 jenes eee d pe PM RUN REVERSE na DETAIL A pair eU RC dM C LE M Ce aM reU zc nni rr Lane onda er l 2 WIRE CONTROL W AUTO START AUTO DIRECTION 2 WIRE CONTROL W AUTO START MANUAL DIRECTION i cR ESL UE a ee gS S a rtm NM nae pS MCN RC C MN M M E l I OFF OFF i l HAND AUTO HAND AUTO FWD REV e E I i I 1 1 1 1 I I jo xt t t t a t O 1A I 1 I F R I 1 I 1 I I l I It ig 1 4 I I NE H hH re a USER SUPPLIED l USER SUPPLIED l Li RF l X 349 I eet em en A D AN ee ee ar mace nee a tee eu E I l l USER SUPPLIED E I loco a S ee ee he se eo eS 4 76 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 APPENDIX B RECOMMENDED COMPONENT LISTS ALTISTART 48 Y Range Soft Start Controllers Appendix B Recommended Component Lists To select control operators push buttons pilot lamps and selector switches control power transformers and wire management devices control and power terminal strips wire terminations indicated on the recommended wiring diagram configurations refer to the latest editions of Square D Schneider Electric s full line product catalogs
50. Y 250 300 500 600 500 800 710 790 1000 ATS48M10Y 350 350 630 800 630 1000 900 1000 1200 ATS48M12Y Table 5 Environmental Characteristics r IP20 for ATS48D17Y to C11Y Degree of protection e IP00 for ATS48C14Y to M12Y A Conforms to IEC 60068 2 27 Shock resistance e 15g 11ms Conforms to IEC 60068 2 6 NCF 20706 and BV1 Vibration resistance 15mm peak from 2 to 13 Hz e 1 gn from 13 to 200 Hz Audible noise measurements taken from 3 ft 1 m away The noise levels may change depending on the fan characteristics e ATS48D17Y to D47Y 52 dBA Soft starter audible noise level ATS48D62Y to C11Y 58 dBA e ATS48C14Y to C17Y 50 dBA e ATS48C21Y to C32Y 54 dBA e ATS48C41Y to C66Y 55 dBA e ATS48C79Y to M12Y 60 dBA Resistance to electrostatic Conforms to IEC 61000 4 2 Level 3 discharges Immunity to radio electric Conforms to IEC 61000 4 3 Level 3 interference Imm nity torapid el ctrica Conforms to IEC 61000 4 4 Level 4 transients 12 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 3 Technical Data Table 5 Environmental Characteristics continued Ambient air temperature Storage e 18t0 158 F 25 to 70 C Operation e 14to 104 F 10 C to 40 C without derating e Up to 140 F 60 C derate the current by 2 for each C above 40 C
51. a Function of Applied Voltage Torque Y 2 TuT 7 di d V Ty Torque developed at V full voltage Tg1 Torque developed with 0 85 V reduced voltage dT tad v Nominal voltage 0 6 V V Reduced voltage 0 Rated 0 025 05 0 75 Seed Figure 18 Torque as a Function of Starting Current Current la lat J Toad ld Starting current at full voltage locked rotor amps Tei s lad Current limit during Soft Start 0 Rated 0 025 05 0 75 1 Speed A soft start progressively increases voltage to the motor By ramping the voltage the ATS48 soft starter limits the amount of current the motor can draw during starting to a user defined setting Figure 18 shows the speed torque characteristics of a motor as a function of starting current The ATS48 soft starter provides optimal acceleration by ramping the acceleration torque within the envelope of curve T When using INTELE braking the stop time t3 is less than the freewheel stopping time t1 INTELE braking is a two part braking process which does not require external components It produces less motor heat than traditional DC injection braking INTELE braking is best used when all of the criteria below are met e 4 pole or 6 pole motors only e motor slip is less than or equal to 3 t sec WK x Arpm 308 x TELT X 0 40 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 3007
52. a hot state Figure 21 Hot Start Curves t s 10000 1000 100 Class 30 Class 25 Class 20 Class 15 Class 10 Class 10A Table 16 Hot Start Trip Time Severe Application Class 20 Thermal Overload Protection Standard Application Class 10 Thermal Overload Protection Sly 5 ly 3 5 ly 5 Iy 23s 75s 32s 15s PTC probes integrated in the motor to measure the motor temperature can be connected to the control card terminals This analog value is managed by the controller The PTC probe thermal overshoot value can be processed and used in two ways To stop the machine in the event of a fault if the signal is active e To activate an alarm if the signal is active This alarm can be displayed in a controller status word serial link or on a configurable logic output NOTE PTC probe protection does not deactivate the motor thermal protection provided by the calculation Both types of protection can operate in parallel 35 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 6 Application and Protection 06 2002 PREVENTIVE MAINTENANCE The following steps should be done at regular intervals 36 Check the condition and tightness of the connections
53. ascade Preheating INTELE braking stop Force freewheel stop Thermal protection Loss of a motor phase Test on small motor Cascade Preheating 3 2 m 1 Motor phase loss not detected Compatible functions Incompatible functions Not significant 2 While the motor is preheating the thermal protection is disabled Set the preheating current IPr 3 In order for this feature to take effect press ENT for 10 s confirmed by flashing display This parameter cannot be modified via the remote keypad display 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 61 ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 7 Programming 06 2002 62 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 8 Fault Management SECTION 8 FAULT MANAGEMENT SOFT STARTER DOES NOT START NO FAULT DISPLAYED NON RESETTABLE FAULTS Table 26 Non Reset Fault Correction Fault Displayed Probable Cause As a general rule if a problem arises when the soft starter is started it is advisable to restore the factory settings and reprogram your settings one by one If this does not fix the problem follow the instructions below Det
54. ay contact life Used in all non reversing logic optional in shunt trip for proper sequencing of contactor logic When energized RCR initiates the start sequence When de energized stopping is initiated Operator controls can be either on off RCR Run Command Relay selector 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 RFR Run Forward Relay Used for reversing applications only this coil duplicates the functionality of RCR for the forward direction and is interlocked with the RFR relay RRR 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 controller fault by the ST Shunt Trip Coil TR timer contact The time delay is to prevent nuisance tripping of the circuit breaker during controller power up or during line undervoltage conditions TR Trip Relay Used in shunt trip circuit breaker logic only coil energized upon a controller fault Used with logic diagrams that use an isolation contactor The fault relay is energized during normal operation and FR Fault Relay deenergizes if the controller fault contacts open or if the motor thermal switch if supplied opens FR a
55. celeration Ed2 20 oy en Time s 0 gt B dE2 I Maximum torque limit 10 to 200 or OFF OFF This limits the torque reference to avoid regenerative behavior in applications with high EL inertia It can be used for constant torque starting if tq2 tLI e OFF no limit e 10to 200 limit set as a percentage of the nominal torque Deceleration gain for torque control 10 to 50 40 This parameter can only be accessed if CLP is set to On and if the StY parameter SEt LE Ig Settings menu is set to d 56 It is used to eliminate instability during deceleration Adjust the parameter in accordance with the oscillations 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming 06 2002 Figure 30 Communication Menu COP Soft starter address Communication speed Communication format Serial link timeout setting Configuration of the link for communication with the remote keypad display or the software workshop LLL Parameters The communication menu parameters can only be modified when the motor is stopped The internal protocol used is MODBUS A WARNING the safe operation of the machine LOSS OF COMMUNICATION CAN CAUSE LOSS OF PROTECTION When using parameter tLP ensure that the time set will not interfere with Failure to f
56. ches may be incapable of completely blocking the motor power should a fault occur auxiliary isolation on the line side of the controller is required Use either a circuit breaker equipped with a shunt trip coil or an electromagnetic contactor Connect the isolation device to the fault relay of the controller so that it opens the controller power circuit in the event of a controller fault The isolation device must be capable of interrupting motor locked rotor current Refer to Appendix A beginning on page 73 for typical circuit diagrams that display the logic controlling the isolation device via the fault relay A CAUTION MOTOR OVERHEATING Failure of the solid state switches on the ATS48 controller can cause single phase operation of the motor Use an isolation device consisting of either a circuit breaker equipped with a shunt trip coil or an electromagnetic contactor to open the line side of the controller The isolation device must be capable of interrupting the motor locked rotor current e 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 23 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 5 Wiring GENERAL WIRING PRACTICES ADAPTATION TO LINE INPUT 24 30072 450 61 06 2002
57. chneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 Table 19 Code ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming Settings Menu SEt Parameters Setting Range Description Factory Setting Nominal motor current 0 4 to 1 3 lg d Adjust the value to the nominal motor current indicated on the motor nameplate In Ensure that the current is between 0 4 and 1 3 lc lc soft starter rating The factory setting corresponds to the usual value of a 460 V standardized motor in accordance with NEC and with Class 10 thermal overload protection 150 to 700 of ly Current limit limited to 500 of 400 of In lc The current limit ILt is expressed as a percentage of ly It is limited to 500 of Ic soft starter rating see Tables 3 and 4 on pages 11 and 12 ILE Current limit ILt x Iy Example 1 ly 22 A ILt 300 Current limit 300 x 22 A 2 66A Example 2 ATS48C21Y with Ic 2 210 A In 195 A ILt 700 Current limit 700 x 195 1365 limited to 500 x 210 1050 A Acceleration ramp time 1to60s 15s This is the rise time of the soft starter torque between 0 and the nominal torque Ty i e the gradient of the torque ramp on acceleration Reference torque asa percentage of T 100 4 EN 80 ALE 60 404 204 Time
58. d return to On using the W button and then press ENT On appears on the screen to indicate that the parameters have been locked e To lock access with a new code when the parameters have been unlocked enter a new code change the number displayed using the 4 or Y keys and press ENT On appears on the screen to indicate that the parameters have been locked e Toclear locking when the parameters have been unlocked return to OFF using the W button and press ENT OFF remains on the screen The parameters are unlocked and will remain unlocked until the next restart Remember to document your access code password Failure to do so could prevent use of the keypad in programming and configuration modes When access is locked using a code only the monitoring parameters can be accessed and with only a temporary choice of parameter displayed 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming The choice of application functions can be limited by the incompatibility between certain functions The functions that are not listed in this table are not incompatible with any other functions Figure 32 Compatibility Functions Soft stop Soft stop INTELE braking stop Force freewheel stop Thermal protection Loss of a motor phase Test on small motor C
59. d aiaa aT 24 Power Connections hihi eel ta ade tere e Anette 25 Control Connections nesnenin a i nennen rennen 29 Layout of Control Terminals sse 30 Soft Starter Applications sssini ciinei ahane reet eta seadeid ni a e 31 Standard Duty Applications eeneenen 31 Severe Duty Applications sseeeeeneenenn 31 Reduced Torque repe ativan ates eed rire ai 31 NTELE M Braking zie ree HR URP 32 Motor Protection and Diagnostics sss 33 Thermal Overload Protection sseeeenenne 33 Motor Thermal Protection with PTC Probes sees 35 Preventive Maintenance sssssseeee eene eee 36 Programming and Setup sess 37 Preliminary Recommendations see 37 Display Unit and Programming n 38 Display Principle ih e e oe erp pe diet tens 38 Lue CD HE 39 Soft Starter Does Not Start No Fault Displayed essesss 63 Non Resettable Faults ececceseeeeesseeeeseceeeeeeeesneneeeseeeenseeeeeeseeeeenenenees 63 Resettable Faults when Causes Disappear see 64 Auto Reset Faults Customer Configurable eese 64 Manual Reset Faults sson Hirini m a aieeaa a aia S 65 Reset Faults Using a Logic Input see 66 Troubleshooting Procedure esseem eere 67 Technical Support
60. dance with the oscillations Activation of the cascade function On OFF OFF e OFF function inactive e On function active This parameter can only be accessed if relay R1 has previously been assigned to the isolation relay function and if the forced freewheel stop and motor preheating functions are not configured in parameters LI3 or LI4 IO menu Assign an input LI LIC 255 motors max UL Line voltage 180 to 790 V 690 V This parameter is used to calculate the power displayed LPr and LAP parameters from the SUP menu The display will only be accurate if this parameter has been set correctly Line frequency 50 60 AUt AUt e 50 50 Hz monitoring tolerance of frequency fault FrF 20 e 60 60 Hz monitoring tolerance of frequency fault FrF 20 e AUt automatic recognition of the line frequency by the soft starter with frequency fault monitoring tolerance FrF 5 Selections 50 and 60 are recommended if the power supply is provided by a generating set given their high tolerance r Pr Reset kWh or the operating time no APH trE no e no function inactive e APH kWh reset to zero e trE operating time reset to zero The reset command must be confirmed with ENT APH and trE take effect immediately The parameter then automatically returns to no FOS Return to factory settings no YES no This is used to reset all parameters to their facto
61. ded by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 5 Wiring Layout of Control Terminals Figure 16 Control Terminals 30072 450 61 06 2002 a m IN lv Je jo lt jo Jae o O Z gt Ix la Ix 2 Jo Jo d 2 je fe 2 o x O o o o fe je amp le b l 5 5 ja S 9 Q a o E E RJ 45 Table 14 Control Terminal Blocks Terminal Function Characteristics 90 to 270 Vac 50 60 Hz CL1 CL2 Control power supply e Switch mode power supply with 25 VA consumption R1A R1C R1 Relay N O programmable contact Minimum switching capacity 10 mA for 6 Vdc R2A R2C R2 Relay N O starting relay contact Maximum switching capacity on inductive load 1 8 A for 230 Vac and 30 Vdc R3A R R3 Relay N O programmable contact SA ASG 8 y N O progr Maximum voltage 400 Vac STOP Stop controller 4 logic inputs with 4 3 kQ impedance RUN Run controller Voltage V 30 V max Current I 8 mA max e State 1 V 11V 1 5mA LI3 L14 Programmable inputs e State 0 V lt 5V lt 2 mA T 24 V 25 isolated and protected against short circuits and overloads maximum current of 24V Logic input power supply 200 mA LO Logic output power supply Connect to 24 V or an external supply source LO1 2 open collector outputs compatible with Level 1 PLC IEC 60065A 68 standard Programmable logic outputs
62. ded in the soft starter via the serial link is incompatible Load a compatible configuration AUTO RESET FAULTS When an auto reset fault appears the soft starter locks and the motor CUSTOM ER CONFIGURABLE Switches to freewheel mode When an auto reset fault occurs the soft starter will automatically restart when the fault has cleared The following are signals that an auto reset fault has occurred e Relay R2 opens e If relay R1 is configured as an isolating relay it opens R1 remains closed if it is configured as a fault relay see page 53 e The fault code flashes on the display as long as the fault is present The last 5 faults are stored and viewable with the PowerSuite software workshop In 2 wire control perform the following steps for any of the faults listed in Table 28 before restarting the soft starter e Remove the cause of the fault Maintain the run command on the RUN input NOTE The soft starter attempts to restart six times at 60 second intervals If the fault is still present at the 6th attempt it trips requiring a manual reset see Manual Reset Faults on page 65 If relay R1 is configured as a fault relay it opens 64 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 8 Fault Management Table 28 Auto Reset Fault Correctio
63. ditions for the end of starting are line voltage applied to the motor min firing angle and motor current less than 1 3 ly e OFF no protection 45 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 7 Programming 06 2002 Table 20 Protection Menu PrO Parameters continued Code Description Setting Range Factory Setting Activation of current overload OFF This function is only active in steady state If the motor current exceeds the threshold setting of parameter LOC for longer than the time parameter tOL is set for one of the following occurs e ALA an alarm activates internal bit and configurable logic output e dEF the soft starter is locked and the OLC fault displays e OFF no protection l4 300 hysteresis LOC 50 gt t detection OIL Current overload threshold 50 to 300 of ly 80 LOC This parameter is not available if OIL is set to OFF LOC can be set from 50 to 300 of the nominal motor current Current overload time 0 1 to 60s 10s This parameter is not available if OIL is set to OFF EOL Time delay tOL activates as soon as the motor current rises above threshold LOC It resets to zero if the current falls below this LOC threshold again by at least 10 hysteresis Protection against line phase inversion 321 1
64. e Unlocked Position O All parameters are accessible Any display restrictions to the starter by the access switch will still be in force once the controller has been disconnected and even if power to the controller is cycled Figure 10 Remote Keypad Display Cable Assembly and Connectors ATS48 controller RJ 45 20 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 SECTION 5 WIRING INSTALLATION PRECAUTIONS 2002 Schneider Electric All Rights Reserved Failure to follow this instruction will result in death serious injury or equipment damage ALTISTART 48 Y Range Soft Start Controllers Section 5 Wiring Good wiring practice requires the separation of control circuit wiring from all power line and load wiring Power wiring to the motor must have the maximum possible separation from all other power wiring Do not run them in the same conduit This separation reduces the possibility of coupling electrical noise between circuits Follow these precautions when installing the ATS48 controller A DANGER HAZARDOUS VOLTAGE Read and understand this manual in its entirety before installing or operating ATS48 controllers Installation adjustment repair and maintenance of these controllers must be performed by qualified personnel The user is responsible for conforming
65. e delay must be set for a time that will allow IC1A complete decay of the motor residual voltage The isolation contactor opens immediately upon a fault The pilot relay IC1A is required when the IC1 contactor coil exceeds the relay rating IC2 Used for reversing applications only the IC2 must be mechanically interlocked to IC1 A reversing contactor may be Isolation Contactor Rev used for the combination of IC1 and IC2 In general the operation of IC2 is identical to IC1 The pilot relay IC1A is IC2A required when the IC1 contactor coil exceeds the relay rating The shorting contactor is used to reduce the heat dissipated by the controller when the motor is operating at full speed and voltage The controller provides proper sequencing of this contactor by the end start up relay When the SC Shorting Contactor and start is completed the shorting contactor will be commanded to close The controller will continue to monitor the SCA Pilot Relay motor thermal state and provide motor overload protection Upon a stop command the SC contactor will open transferring the motor current to the SCRs to allow for controlled deceleration if desired The pilot relay SCA is required when the SC contactor coil exceeds the relay rating Transient suppression of all relay and contactor coils except ST is recommended to minimize the possibility of TS Transient Suppressors ils z A electrical interference with the controller electronics and to increase rel
66. e of up to 60 C as long as the maximum current rating for Class 10 thermal overload protection is derated by 296 for each degree above 40 C without a shorting bypass contactor or by 2 for each degree above 50 C with a shorting bypass contactor The nominal motor current ly must not exceed the maximum current rating for Class 10 thermal overload protection Table 3 Standard Duty Application 208 to 690 V Supply 10 to 1596 50 or 60 Hz npo npe pies ApS kwe npe Ee ft ess dU TER Ic Rating Catalog Number 208 V 230 V 440 V 460 V 500 V 575 V 690 V Overload Protection 5 7 5 10 9 15 15 17 17 ATS48D17Y 7 5 11 15 11 20 18 5 22 22 ATS48D22Y 75 10 15 20 18 5 25 22 32 32 ATS48D32Y 10 m 18 5 25 22 30 30 38 38 ATS48D38Y 15 22 30 30 40 37 47 47 ATS48D47Y 15 20 30 40 37 50 45 62 62 ATS48D62Y 20 25 37 50 45 60 55 75 75 ATS48D75Y 25 30 45 60 55 75 75 88 88 ATS48D88Y 30 40 55 75 75 100 90 110 110 ATS48C11Y 40 50 75 100 90 125 110 140 140 ATS48C14Y 50 60 90 125 110 150 160 170 170 ATS48C17Y 60 75 110 150 132 200 200 210 210 ATS48C21Y 75 100 132 200 160 250 250 250 250 ATS48C25Y 100 125 160 250 220 300 315 320 320 ATS48C32Y 125 150 220 300 250 350 400 410 410 ATS48C41Y 150 250 350 315 400 500 480 480 ATS48C48Y 200 355 400 400 500 560 590 590 ATS48C59Y 200 250 400 500 600 630 660 660 ATS48C66Y 250 300 500 600 500 800 710 790 790 ATS48C79Y 350 350 630
67. ed from the bottom controller can adversely affect the ambient temperature around the top controller A CAUTION CONTROLLER OVERHEATING Mount the ATS48 controller within 10 of vertical Do not locate the controller near heat radiating elements e Electrical current through the controller will result in heat losses that must be dissipated into the ambient air immediately surrounding the controller To 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 2002 Schneider Electric All Rights Reserved 17 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 4 Mounting Mounting in a General Purpose Metal Enclosure Soft Starter Ventilation Mounting in a Dust and Damp Proof Metal Enclosure Figure8 X Ventilation for Dust and Damp Proof Enclosure Si lt 60 C l ATS48 controller 0 i internal ambient temperature 0 e external ambient temperature 18 30072 450 61 06 2002 Follow the instructions in this section in order to meet NEMA Type 1 IP23 degree of protection To ensure adequate air flow inside the controller follow these guidelines Leave sufficient space around the controller see Figure 7 e Ensure suffic
68. ermine whether or not the code displayed corresponds to the normal state of the soft starter see Table 17 on page 38 If no fault is displayed and the soft starter does not start e Check that the line supply is present on the control supply CL1 CL2 see page 30 e Check for the presence of the RUN STOP commands see Appendix A When a non resettable fault appears the soft starter locks and the motor switches to freewheel mode The following are signals that a non reset fault has occurred Relay R2 opens e After the soft starter locks Relay R1 opens e The fault code flashes on the display The last 5 faults are stored and viewable with the PowerSuite software workshop Do the following before restarting the soft starter e Remove the fault cause s see Table 26 e disconnect and reconnect the control supply Corrective Action Disconnect and reconnect the control supply If the fault persists hop Interinal fault contact Schneider Electric product support Overcurrent Disconnect power to the soft starter then e impeding short circuit on soft starter output e Check the connecting cables and the motor isolation OEF e internal short circuit e Checkthe thyristors e bypass contactor stuck e Check the bypass contactor for a stuck contact e softstarter is overloaded e Checkthe parameter value bSt in the menu drC page 49 Phase inversion Pp The line phase inversion does not conform to the PHr parameter
69. es for a basic contactor assembly minus the power connection links and terminals are indicated before each part number Refer to the latest editions of Square D Schneider Electric s full line product catalogs for power connector link and terminal kits Reversing contactor interlock units used for the C79 through M12 controllers are designed for vertical interlocking of the individual contactors Horizontally interlocked contactors are used for D17 through C59 controllers The D Line contactor is available as a reversing configuration For these applications change the IC1 part number prefix from LC1 to LC2 to order the IC1 and IC2 combination complete with mechanical interlocks Electrical equipment should be installed operated serviced and maintained only by qualified personnel No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material D SQUARE D 2003 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 Instruction Bulletin oei20g2 Raleigh NC USA ALTISTART 48 Y Range Soft Start Controllers Installation Guide Retain for future use D SQUARE D This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 TABLE OF C
70. fter LI3 or LI4 have been assigned to function LIH motor preheating Preheating starts when the input activates after time delays tPr and tbS PrO menu have elapsed 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 Table 22 Code ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming 1 0 Menu IO Parameters continued Description Setting Range Factory Setting tal Logic outputs ri e no not assigned e tAl motor thermal alarm see page 33 LU je ml motor powered Loe l AIL motor current alarm threshold OIL and time tOL of PrO menu exceeded See page 46 e AUL motor underload alarm threshold LUL and time tUL of PrO menu exceeded See page 45 e APC motor PTC probe alarm See PtC on page 46 e AS2 second set of motor parameters activated See LIS on page 52 Relay R1 nF e r1F fault relay In this mode relay R1 activates when the soft starter is powered up minimum CL1 CL2 control Relay R1 deactivates when a fault occurs and the motor switches to freewheel mode See the special case when the automatic restart function is activated and E Fault Management on page 63 e rl isolation relay Relay R1 is designed to control the line contactor on the basis of the RUN and STOP commands and to indicate
71. horting bypass contactors must be used Fuse selections in Table 8 are based upon 150 of nominal motor current Ferraz Shawmut fuses are recommended for the overcurrent protective device OCPD Table 8 Short Circuit Protection Device Type 1 Coordination Short Circuit Current Recommended OCPD Rating A 9 Catalog Number Fuse Class Rating 575 V Time Delay ia 208 V 230 V 460 V 575 V ATS48D17Y J 5000 15 20 20 25 ATS48D22Y J 5 000 25 30 30 30 ATS48D32Y J 5 000 35 40 40 40 ATS48D38Y J 5 000 45 md 50 45 ATS48D47Y J 5 000 60 60 60 ATS48D62Y J 5 000 70 80 80 80 ATS48D75Y J 10 000 90 100 100 90 ATS48D88Y J 10 000 110 125 110 110 ATS48C11Y J 10 000 125 150 150 150 ATS48C14Y J 10 000 175 200 175 175 ATS48C17Y J 10 000 200 225 225 225 ATS48C21Y J 10 000 250 300 250 300 ATS48C25Y J 18 000 300 350 350 350 ATS48C32Y J 18 000 400 450 450 400 ATS48C41Y J 18 000 500 500 600 500 ATS48C48Y i e i p 18 000 600 650 600 ATS48C59Y L 30 000 700 700 700 ATS48C66Y L 30 000 750 900 800 800 ATS48C79Y L 42 000 1000 1000 1000 1100 ATS48M10Y L 85 000 1350 1200 1400 1400 ATS48M12Y L 85 000 1500 1600 1600 1600 14 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 3 Technical Data DIMENSIONS AND WEIGHTS Figure 4
72. ient temperature indicated in the table represents the temperature of the air surrounding the ATS48 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 controller For operating ambient above 40 C without a shorting bypass contactor and 50 C with a shorting bypass contactor but not exceeding 60 C the rated current Ic of the controller must be de rated by 2 per C 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 77 ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Appendix B Recommended Component Lists 06 2002 Table 33 Additional Suggested Components for Standard Duty Applications me Ici 23 Ic2 123 sc 23 Fusible Disconnect Man Controller Isolation Reversing Mechanical Shorting power Fuses 7 Molded Case Ce Model Contactor Contactor Interlock ACH Class Rating Fuse Block Switch 9 Breaker 8 5 D17Y LC1D18 LC1D18 9 LC1D18 J 25 60308J FHL36000M FAL36030 D22Y LC1D25 LC1D25 9 LC1D25 J 30 60308J FHL36000M FAL36040 D32Y LC1D32 LC1D32 9 LC1D32 J 40 60608J FHL36000M FAL36050 D38Y LC1D40 LC1D40 9 LC1D40 J 50 60608J FHL36000M FAL36060 D47Y LC1D50 LC1D50 9 LC1D50 J 60 60608J FHL36000M FAL36080 D62Y LC1D65 LC1D65 9 LC1D65 J 80 61038J F
73. ient ventilation If necessary install a cooling fan with filters Figure 7 Ventilation and Clearances 4 in 100 mm 2in 50 mm 0 lt 40 C 0 lt 40 C 71014 ikke 2in V 50 mm 100 mm 4in 100 mm On soft starters fitted with a cooling fan the fan switches on automatically as soon as the heatsink temperature reaches 50 C It is switched off when the temperature drops to 40 C Table 11 Fan Flow Rates Part Number CFM m hour ATS48D32Y and D38Y 24 14 ATS48D47Y 48 28 ATS48D62Y to C11Y 146 86 ATS48C14Y and C17Y 235 138 ATS48C21Y to C32Y 476 280 ATS48C41Y to C66Y 1020 600 ATS48C79Y to M12Y 2040 1200 Follow the instructions in this section in order to meet NEMA Type 12 IP54 degree of protection Maintain clearances as shown in Figure 7 Do not use insulated or non metallic enclosures as they have poor thermal conduction Provide a stirring fan to circulate air inside the enclosure and prevent hot spots in the controller as shown in Figure 8 This allows operation of the soft starter in an enclosure with a maximum internal temperature of 140 F 60 C Ensure that the ambient temperature around the soft starters does not exceed this limit To reduce temperature rise within the enclosure use a shorting bypass contactor duty cycle not to exceed 2 starts per hour or a heat exchanger Derate the soft starter current I by 2 per
74. ink LEE Last fault detected see page 63 If no faults have been saved the display shows n UF 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 59 ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming 60 Table 25 Code 30072 450 61 Parameter 06 2002 Parameter Displayed Menu SUP Parameters continued Unit PHE Cid Phase rotation direction as viewed from the soft starter e 123 forward L1 L2 L3 e 321 reverse L3 L2 L1 Keypad display locking code enables the soft starter configuration to be protected using an access code password OFF no access locking codes e To lock access enter a code 2 to 999 The number displayed can be increased using the 4 key Now press ENT On appears on the screen to indicate that the parameters have been locked On a code is locking access 2 to 999 e To unlock access enter the code increasing the number displayed using the A key and press ENT The code remains on the display and access is unlocked until the next power down Parameter access will be locked again on the next power up e If an incorrect code is entered On appears on the display and the parameters remain locked XXX parameter access is unlocked the code remains on the screen e To reactivate locking with the same code when the parameters have been unlocke
75. lerates too quickly Estimated torque as a percentage 4 of the nominal torque 100 dEL 80 60 40 20 Time s 0 E dEC I Final deceleration torque 0 to 100 20 This parameter can only be accessed if StY is set to d and if the CLP parameter in the drive menu drC is still set to On the factory setting Selects the final torque level 0 and 100 of estimated torque during a type d stop This is the threshold at which the controlled stop ends and the freewheel portion of the stop begins If the estimated torque at the start of deceleration is below 20 i e 20 of the nominal torque controlled deceleration is not activated and the motor changes to freewheel mode Estimated torque as a percentage of the nominal torque EdE 100 804 60 End of controlled deceleration 40 m EdC 7 Time s ais Toy 5 0 T s L dEC 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 2002 Schneider Electric All Rights Reserved ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming Table 19 Settings Menu SEt Parameters continued Code Description Setting Range Factory Setting Internal braking torque level 0 to 100 This parameter can only be accessed if StY is set to b Selects the braking torque level for
76. ller is available in twenty one current ratings from 17 to 1200 A All models use a common control interface for consistent and simple set up ATS48 controllers are rated for use with 208 to 690 V motors and are self adjusting for a 50 or 60 Hz supply frequency This instruction bulletin covers the technical characteristics specifications installation wiring programming and troubleshooting of all ATS48 controllers Many option kits are available for the ATS48 controllers Refer to Appendix C beginning on page 79 Some of the terms and acronyms used in this manual are defined in Table 2 Table 2 Definition of Terms Term Definition FLA Full load amps the current rating of an induction motor at rated speed and load This value may be found on the motor nameplate Nominal current rating of the ATS48 controller This value may be found on the controller nameplate In User defined motor current rating Same as FLA Tn Nominal motor torque as calculated by the ATS48 controller Nominal voltage of supply power mains supply This should correspond to the motor rated voltage on the motor nameplate This is a new document Before installing the ATS48 controller read this manual and follow all precautions Before removing the ATS48 controller from its packing material verify that the packing carton is not damaged from shipping Damage to the packing carton usually indicates improper handling If any damage is fou
77. lso provides additional contacts for the controller fault output To select control operators push buttons pilot lamps and selector switches control power transformers and wire management devices control and power terminal strips wire terminations indicated on the recommended wiring diagram configurations refer to the latest editions of Square D Schneider Electric s full line product catalogs 2002 Schneider Electric All Rights Reserved 73 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Appendix A Recommended Wiring Diagrams Figure 33 Circuit Breaker w Shunt Trip Nonreversing with Shunt Trip Fault Isolation 1 1 30072 450 61 06 2002 ATS48 CONTROLLER END START UP PROGRAMMABLE N O CONTACT Control circuit connection for 460 V operation Reconnect as required for other voltages For shorting contactor operation add SC with associated control circuit Relay contact located on ATS48 controller Located at motor Jumper if switch not present Use RCR relay logic for ATS48 2 wire or 3 wire control when using shorting contactor User supplied AC LINE 3 L2 SUPPLY Li Ld 1 FUA l lt TOCONTRO
78. menu page 45 Make sure the soft starter and motor are sized properly for the load and application OLE Current overload Check the mechanism for wear mechanical play lubrication blockages etc Check the value of parameters LOC and tOL in the PrO menu page 46 OLF Motor thermal fault Check the mechanism for wear mechanical play lubrication blockages etc Make sure the soft starter and motor are sized properly for the load and application Check the value of parameter tHP in the PrO menu page 45 and that of parameter Iy in the SEt menu page 41 Check the electrical isolation of the motor Wait for the motor to cool before restarting OEF Motor thermal fault detected by the PTC probes Check the mechanism for wear mechanical play lubrication blockages etc Make sure the soft starter and motor are sized properly for the load and application Check the value of the PtC setting in the PrO menu page 46 Wait for the motor to cool before restarting ULF Motor underload Check the hydraulic circuit Check the value of parameters LUL and tUL in the PrO menu page 45 Locked rotor in steady state This fault is only active in steady state with soft starter bypass contactor It is detected if the current in a phase is greater than or equal to 5 Iy for more than 0 2 s RESET FAULTS USING A LOGIC INPUT 66 Check the mechanism for wear mechanical play lubrication bl
79. n 2 wire control Fault Displayed Probable Cause Corrective Action Check the line the connection to the soft starter and any Loss of a line phase isolating devices located between the line and the soft starter such as contactors fuses and circuit breakers e Check the motor connection and any isolating devices PHF Loss of a motor phase A located between the soft starter and the motor such as If the motor current falls below an adjustable threshold PHL for 0 5 s contactors fuses and circuit breakers single phase or for 0 2 s 3 phase This fault can be configured in Check the motor state the Protection menu PrO parameter PHL Ensure that parameter PHL is compatible with the motor Line frequency is out of tolerance e Check the line EE This fault can be configured in the Advanced settings menu drC Ensure that parameter FrC is configured properly for the parameter FrC line used generating set for example For any of the faults listed in Table 29 perform the following steps before restarting the soft starter e Remove the cause of the fault e n2 wire control maintain the run command Table 29 Auto Reset Fault Correction Fault Displayed Probable Cause Corrective Action USF Power supply fault on a run command Check the power supply circuit and voltage CLF Control line failure Loss of CL1 CL2 for more than 200 ms If the automatic restart function is not selected see Manual Reset Faul
80. n and deceleration CAUTION EQUIPMENT DAMAGE HAZARD Do not connect power factor correction capacitors to the load side power circuit of the ATS48 controller Failure to follow this instruction can result in injury or equipment damage The ATS48 controller uses solid state power switches to control motor power When checking the condition of conductor or motor insulation do not connect the high potential dielectric test equipment or insulation resistance tester to the controller since the test voltages used may 22 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 2002 Schneider Electric All Rights Reserved ALTISTART 48 Y Range Soft Start Controllers Section 5 Wiring damage the controller Always disconnect the controller from the conductors or motor before performing such tests A CAUTION EQUIPMENT DAMAGE HAZARD e Do not perform high potential dielectric tests on circuits while the circuits are connected to the ATS48 controller Any circuit requiring high potential dielectric tests must be disconnected from the controller prior to performing the test Failure to follow this instruction can result in injury or equipment damage The ATS48 controller contains electronic protection to detect and signal failure of the solid state switches Since the solid state swit
81. n contact per Figure 1 Figure 1 Corrections to Figure 34 Figure 2 Corrections to Figure 33 EM L pel E a J 11 Ti 11 E L e pom A J 1 I I s FU4 Fus lt LULA Q Gee a uu So 2 Sa l m s TOR fee AY Ss ue di e m 3 i 8 FU1 FUA FUS e Casas D T81 FAULT RCR R1A RIC A RIO f UN d FR d I VLA FR TS1 b FR RCR y ex l re fS i CB SHUNT TS2 9 F i W i TRIP COIL END 2003 Schneider Electric All Rights Reserved D SQUARE D This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ERRATA for bulletin 30072 450 61 Errata Square D Company 8001 Highway 64 East Knightdale NC 27545 USA 1 888 SquareD 1 888 778 2733 www SquareD com 30072 450 87 04 2003 Page 77 in Table 32 Suggested Components for Standard Duty Applications Under Control fuses FU4 FU5 replace 0 25 A with 0 5 A UL Class CC 600 V time delay fuses Page 78 in Table 33 Additional Suggested Components for Standard Duty Applications New IC1 IC2 and SC component selections apply See Table 1 Table 1 Corrections to Table 33 Ic1 23 Ic2 123 sc 23 ATS48 Controller Isolation Reversing Mechanical Shorting Model Contactor Contactor 9 Interlock Contactor AC1 D17Y LC1D12G7 LC1D12G7 3 LC1D12G7 D22Y LC1D18G7 LC1D18G7 9 LC1D1
82. nal motor current indicated on the motor nameplate Ensure that the current is between 0 4 and 1 3 Ic soft starter rating See Tables 3 and 4 on pages 11 and 12 NOTE The factory setting of In2 corresponds with the usual value of a 460 V standardized motor in accordance with NEC and with Class 10 thermal overload protection 150 to 700 of In limited to 500 of 400 of ly lcu Current limit The Current limit IL2 is expressed as a percentage of In2 It is limited to 500 of Ic see Tables 3 and 4 on pages 11 and 12 Current limit 2 IL2 x In2 Example 1 In2 21 A IL2 300 Current limit 30096 x 22 A 66 A Example 2 ATS48C21Y with Ic 210 A In2 195 A IL2 700 Current limit 700 x 195 1365 limited to 500 x 210 1050 A Ale Acceleration ramp time 1to60s 15s This is the rise time of the soft starter torque between 0 and the nominal torque Ty i e the gradient of the torque ramp on acceleration Reference torque 4 as a percentage of Ty 100 80 60 40 20 Time s gt 0 AC2 m Ege 2002 Schneider Electric All Rights Reserved Initial starting torque 0 to 100 of Ty 20 Initial torque setting during the starting phases varies from 0 to 100 of the nominal torque Cn 4 Time s 0 AC2 55 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp c
83. nal to start the system Table 1 Factory Configuration preset to correspond to 460 V rated motor current based on Nominal motor current IN NEPA 70 NEC Table 430 150 ratings Current Limit ILt 400 of the motor current Iy Acceleration ramp ACC 15 seconds Initial torque on starting 20 of the nominal torque tq0 6 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 1 Quick Start Procedure Table 1 Factory Configuration continued Stop StY Freewheel stop F Motor thermal protection Class 10 thermal overload protection curve tHP 1 rdY soft starter ready when power and control voltage are Display i present and the motor is operating Logic inputs LH e STOP e LI2 e RUN e LIZ e Forced freewheel stop LIA e Ll4 e Forced local mode LIL Logic outputs e LO1 e LO2 Motor thermal alarm tA1 Motor powered rnl Relay outputs e Ri e R2 e R3 Fault relay r1F Bypass relay at the end of starting Motor powered rnl Analog output AO Motor current OCr 0 20 mA Communication parameters 2002 Schneider Electric All Rights Reserved When connected via the serial link the soft starter has a logic address Add of 0 Transmission speed tbr 19200 bits per second Communication format F
84. nd notify the carrier and your Square D Schneider Electric representative After removing the ATS48 controller from its packaging inspect it for damage If any shipping damage is found notify the carrier and your sales representative Verify that the ATS48 controller nameplate and label conform to the packing slip and corresponding purchase order This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 2 Receiving and Handling STORING AND SHIPPING HANDLING THE CONTROLLER Figure 3 Hoisting the ATS48 Controller 10 30072 450 61 06 2002 A CAUTION EQUIPMENT DAMAGE HAZARD Do not operate or install any controller that appears damaged Failure to follow this instruction can result in injury or equipment damage If the ATS48 controller is not being immediately installed store it in a clean dry area where the ambient temperature is between 13 and 158 F 25 and 70 C If the ATS48 controller must be shipped to another location use the original shipping material and carton to protect it Do not remove the ATS48 controller from the carton until it is at the final installation site The carton provides protection and 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
85. njury Table 20 Protection Menu PrO Parameters Code Description Setting Range Factory Setting Motor thermal protection 10 See Thermal Overload Protection on page 33 e 30 Class 30 e 25 Class 25 LHP 20 Class 20 severe application e 15 Class 15 e 10 Class 10 standard application e 10A Class 10A e 2 Sub class 2 e OFF no protection Activation of motor underload OFF If the motor torque is less than threshold setting of parameter LUL for longer than the time parameter tUL is set for one of the following occurs e ALA an alarm activates internal bit and configurable logic output e dEF the soft starter is locked and the ULF fault displays e OFF no protection T Cn 100 j H ULL TM hysteresis eee LUL 20 7 detection ULL t Motor underload threshold 20 to 100 of Ty 60 LLL This parameter is not available if ULL is set to OFF LUL can be set from 20 to 100 of the nominal motor torque Motor underload time 1to60s 60s EUL This parameter is not available if ULL is set to OFF Time delay tUL activates as soon as the motor torque falls below threshold LUL It resets to zero if the torque rises above this LUL threshold by 10 hysteresis Excessive starting time 10 to 999 sor OFF OFF If the starting time exceeds the value of tLS the soft starter is locked and displays the EL 5 fault StF The con
86. ockages etc If a logic input LI is configured to reset motor thermal fault LIt or any other resettable fault Llr for the motor to restart the following conditions must be met e The soft starter must send a pulse on logic input LI e n2 wire control the run command must be maintained on the RUN input e n 3 wire control a new run command rising edge must be initiated on the RUN input 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 TROUBLESHOOTING PROCEDURE TECHNICAL SUPPORT 2002 Schneider Electric All Rights Reserved ALTISTART 48 Y Range Soft Start Controllers Section 8 Fault Management When troubleshooting the soft starter discuss the symptoms of the reported problem with the operating personnel Ask the operator to describe the problem and to identify when and where it first occurred Then directly observe the controller and process Copy the Troubleshooting Sheet on page 68 and use it to record the controller motor and peripheral equipment nameplate data For more information call fax or write Square D Schneider Electric Technical Support 8001 Highway 64 East Knightdale NC 27545 9023 Telephone 919 266 8600 or 1 888 SQUARED 1 888 778 2733 Fax 919 217 6508 e Mail drivespsg squared com 67 This document provided by Barr Thorp Electric Co Inc 800 473 9123 ww
87. of the nominal 2002 Schneider Electric All Rights Reserved value of the parameter configured or if the parameter is power factor of 1 for the power factor 53 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming 54 Figure 29 Nominal motor current Current limit Acceleration ramp time Initial starting torque Deceleration ramp time Threshold for changing to freewheel stop mode at the end of deceleration Maximum torque limiting Deceleration gain dee ee Edge C Parameters Bede 4 Parameter availability is dependent on the StY setting in the SET menu 30072 450 61 Second Motor Parameters Menu St2 On the next acceleration ie Immediately Immediately On the next deceleration This menu is only visible if a logic input is assigned to the function for activating a second set of motor parameters LIS in the I O menu This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 06 2002 2002 Schneider Electric All Rights Reserved 30072 450 61 06 2002 Table 23 Code ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming Second Motor Parameters Menu St2 Parameters Description Factory Setting Setting Range Nominal motor current 0 4 to 1 3 lo See note Adjust the value of the nomi
88. ollow this instruction can result in death or serious injury Table 24 Communication Menu COP Parameters Code Description Setting Range Factory Setting Add Soft starter address by the RS 485 serial link 0 to 31 0 Ebr Communication speed in kbps 4 8 9 6 19 2 19 2 Communication format 801 8 data bits odd parity 1 stop bit Pur 8n1 8E1 8 data bits even parity 1 stop bit 8n1 8 data bits no parity 1 stop bit 8n2 8 data bits no parity 2 stop bits 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 57 ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming 30072 450 61 06 2002 Table 24 Communication Menu COP Parameters continued Code Description Setting Range Factory Setting EL P Serial link timeout setting 0 1 to 60 s 5s Configuration of the serial link for communication with the remote keypad display e On function active Temporarily configures the soft starter tbr PLE and FOr for communication with the OFF Figure 31 PCt returns to the OFF state as soon as the control voltage is disconnected On the next power up the tbr and FOr parameters return remote keypad display OFF function inactive to their initial configuration Parameter Displayed Menu SUP Power factor Motor thermal state as a percent Motor current Operating time
89. om ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming 30072 450 61 06 2002 Table 23 Second Motor Parameters Menu St2 Parameters continued Code Description Setting Range Factory Setting 1 to 60s Deceleration ramp time 15s This parameter can only be accessed if StY is set to d It sets a time from 1 to 60 s to switch from the estimated torque to zero torque gradient of the torque ramp on deceleration when a d stop is applied This modifies the progression of the deceleration and avoids hydraulic shocks in pump applications by modifying the gradient of the torque reference Estimated torque as a percentage 100 of the nominal torque dEg 80 60 40 20 Time s 0 L dE2 Final deceleration torque 0 to 100 20 This parameter can only be accessed if StY is set to d and if the CLP parameter in the drive menu drC is still set to the factory setting On It sets the final torque level from 0 and 100 of the torque estimated at the beginning of deceleration In pump applications deceleration control is not necessarily below a load level set by Ed2 If the estimated torque at the start of deceleration is below 20 i e 20 of the nominal torque controlled deceleration does not activate and the motor changes to freewheel mode Estimated torque as a percentage Eda 400 4 of the nominal torque 804 60 40 End of controlled de
90. on page 50 Programming the ATS48 controller is simplified by internal sequence selections and interlocks For ease of setup Square D recommends accessing the menus in the following order 1 lO Assignment of the inputs outputs 2 drC Advanced settings 3 SEt Settings Some steps may not be necessary Copy and use the Factory Settings table on pages 69 72 to record your settings 37 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 7 Programming 06 2002 DISPLAY UNIT AND PROGRAMMING Figure 22 Display Functions mer pem 3 seven segment displays Enters a menu or a parameter or saves the displayed parameter or value Returns to the previous menu or parameter or increases the displayed value Goes to the next menu or parameter Exits a menu or parameter or aborts the displayed or decreases the displayed value value to return to the previous value in the memory NOTE Pressing A or does not store the choices To store the displayed choice press 6 The display flashes when a value is stored Display Principle The display principle for numbers differs depending on the maximum scale of the parameter and its value see Table 17 for examples Table 17 How to Read Displayed Numbers Example Range Display Value Max scale 9990 05 5 5 5 0 1 to 99 9 55 0 55 55 5 55 5 10
91. or protection is provided externally The various thermal overload protection classes are defined to meet the standards of IEC 60947 4 2 for starting from both cold and hot states A cold state is defined as the stabilized motor thermal state when the motor is off Figure 20 shows the approximate trip times for starting from a cold state Figure 20 Cold Start Curves t s 10000 1000 100 ass 30 ass 25 ass 20 ass 15 S O O OOO ass 10 o ass 10A 1 Class 2 0 5 112 1 5 2 00 250 3 00 3 50 4 00 4 50 5 00 5 50 6 00 6 50 7 00 7 50 8 00 Vn Table 15 Cold Start Trip Time Standard Application Class 10 Severe Application Class 20 Thermal Thermal Overload Protection Overload Protection 3 In 5 In 3 5 In 5 In 46s 15s 63s 29 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 Motor Thermal Protection with PTC Probes 2002 Schneider Electric All Rights Reserved ALTISTART 48 Y Range Soft Start Controllers Section 6 Application and Protection Hot state is defined as the stabilized motor thermal state when the motor has been running at full load capacity Figure 21 shows the approximate trip times for starting from
92. owerSuite Software for Personal Computers PowerSuite Test and Commissioning Software on CD for use with Microsoft Windows 95 98 and NT and Windows CE v3 0 for rene A Pocket PCs PDA Cable connection kit for the Personal Computer to an ATS48 controller VW3A8106 e two connection cables 9 8 ft 3 m each with two RJ 45 connectors e one RJ 45 9 way SUB D adaptor e one converter marked RS 232 RS 485 PPC with one 9 way male SUB D connector and one RJ 45 connector Factory repaired ATS48 controllers are available within 24 hours from a factory exchange pool or your ATS48 controller can be factory repaired and returned Contact your local Square D Schneider Electric Distributor or 2002 Schneider Electric All Rights Reserved 79 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Appendix C Options And Accessories 06 2002 Square D Schneider Electric Customer Service Representative at 919 266 8666 for availability 80 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 INDEX A AC2 55 ACC 41 Add 57 AIL 53 AO 53 APC 53 ArS 47 AS2 53 ASC 53 AUL 53 brC 43 bSt 49 C CFF 64 CFI 64 circuit breaker 78 CLF 65 CLP 49 COd 60 contactor isolation 78 reversing 78 shorting 78 COS 59 CSC 5
93. protection for motor Class 2 10 10A 15 20 25 30 or no protection and or thermal protection with positive temperature coefficient PTC probes e Motor underload settings e Ourrent overload settings e Phase reversal e Phase loss e Automatic restart 13 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers 30072 450 61 Section 3 Technical Data 06 2002 The ATS48 controllers conform to IEC 60947 4 2 EMC In steady state they emit a level of interference below the allowable levels defined in the standard Table 7 Electromagnetic Compatibility EMC Examples Standards Test Levels sources of interference IEC 61000 4 2 Level 3 Electrostatic discharge e through contact e through air Contact with an electrically charged 6kV person 8kV IEC 61000 4 3 Level 3 Radiated electromagnetic fields Equipment transmitting radio 10 V m frequencies Immunity tests IEC 61000 4 5 Level 4 Rapid electrical transients e Power supply cables AkV Opening closing of a contactor e Control supply cables 2kV IEC 61000 4 5 Level 3 Shock wave e Phase to Phase 1kV e Phase to Ground 2 kV IEC 61000 4 12 Level 3 Damped oscillating waves 1kV 1 MHz Oscillating circuit on the line supply Radiated and conducted IEC 60947 4 2 Class A emissions IEC 60947 4 2 Class B on soft starters up to 170 A ATS48D17Y to C17Y s
94. que bre Internal braking torque level 50 0 to 100 EBA Injection time at the end of braking 20 20 to 100 EHP Motor thermal protection 10 OFF 2 10A 10 20 25 or 30 OFF ULL Activation of motor underload OFF dEF treated as fault ALA treated as alarm LUL Motor underload threshold 60 20 to 100 of In E UL Motor underload time 60 1to60s ELS Excessive starting time OFF OFF 10 to 999 s ALA treated as alarm O IL Activation of current overload OFF dEF treated as fault OFF no protection 3c 5 2 L OE Current overload threshold 80 50 to 300 of In z z9 EOL Current overload time 10 0 1 to 600 s 2 p o n n 321 reverse L3 L2 L1 PHr Protection against line phase inversion no 123 forward L1 L2 L3 no no monitoring EAS Time before starting 2 0 to 999s PHL Phase loss threshold 10 5 to 10 Activation of motor monitoring by PTC Ore PEC r bss g5y OFF dEF treated as fault P ALA treated as alarm Ares Automatic restart OFF OFF On E H Reset motor thermal state No No YES 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 69 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 8 Fault Management FACTORY SETTINGS continued 30072 450 61 06 2002 Code Designation Factory Setting Customer Setting Parameter Range and Units Ec AT Torque limit OFF OFF 10 to 200 of Ty HS
95. removed from the carton the controller can be handled e With a hoist When hoisting the controller attach a spreader bar to the two lifting holes on top of the controller as shown in Figure 3 e na horizontal position with the back of the controller resting on a pallet The ATS48 range comprises 6 sizes with various weights and dimensions Small controller can be removed from their packaging and installed without a handling device A handling device must be used with large controllers for this reason they are supplied with lifting holes NOTE Do not rest the unit directly on the bus bar connectors A WARNING HANDLING AND LIFTING HAZARD Keep the area below any equipment being lifted clear of all personnel and property Use the lifting method shown in Figure 3 Failure to follow this instruction can result in death or serious injury 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 3 Technical Data SECTION 3 TECHNICAL DATA TECHNICAL CHARACTERISTICS Tables 3 and 4 describe the technical characteristics of the ATS48 controller The information is based on operation at a maximum ambient temperature of 40 C without a shorting bypass contactor and at 50 C with a shorting bypass contactor The ATS48 controller can be used in an ambient temperatur
96. ron motor frame The second T2 represents the temperature rise of copper stator windings For each thermal image two levels of alarm are detected An overload pre alarm is signaled by logic output LO1 when the motor has exceeded its nominal temperature rise threshold A pre alarm is signaled when the thermal state exceeds 105 for T1 and or 130 for T2 A thermal fault signal stops the motor when the temperature rise exceeds the critical threshold A thermal fault is signaled by relay R1 when the motor thermal state exceeds 110 for T1 and 140 for T2 Figure 19 Thermal Trip Curves 60 mn 5mnj Pre alarm VI The ATS48 controller is preset to provide Class 10 thermal overload protection for standard duty applications The ATS48 controller can be adjusted to provide Class 2 10A 10 15 20 25 or 30 thermal overload protection as necessary Class 2 protection is available for applications such as submersible pumps where very tight control of motor temperature is required Class 30 protection is available for applications such as high inertia 33 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 6 Application and Protection 30072 450 61 06 2002 loading where a longer than normal starting time is required to accelerate the load to full speed In addition the internal overload protection may be disabled if mot
97. rting if tqO tLl e OFF no limit e 10to 200 limit set as a percentage of the nominal torque b5t Voltage boost level 50 to 100 or OFF OFF If active this parameter applies a user set voltage when a run command is present for 100 ms Once this time has elapsed the soft starter follows a standard acceleration ramp starting at the initial torque value set tq0 This function can be used to avoid any starting torque phenomenon caused by friction on stopping or by mechanical play e OFF Function inactive e 50 to 100 setting as a percentage of the nominal motor voltage Uy T 100 4 Ts Un Torque ramp 50 T Un tqd L 100 ms t NOTE When overrating the soft starter Im motor Im ATS48 soft starter if the bSt value is set too high the soft starter can nuisance trip as an overcurrent OCF fault SSE Tests on small motor On OFF OFF Use this parameter to check the soft starter in a testing or maintenance environment on a motor whose power is very much lower than the soft starter rating in particular for high power soft starters It automatically deactivates the torque control parameter CLP e OFF function inactive e On function active SSt returns to the OFF state as soon as the control voltage is disconnected On the next power up the PHF fault and the CLP parameter return to their initial configuration LLP Torque control type of control
98. ry settings e no function inactive e YES function active must be pressed and held down for approx 2 s in order to be accepted The display flashes to confirm The FCS parameter then automatically resets to no when you press ESC This parameter cannot be modified via the remote keypad display 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 ALTISTART 48 Y Range Soft Start Controllers 06 2002 Section 7 Programming Figure 28 1 O Menu IO n IIO Assignment of logic input LIB 73 L ar OIC Assignment of logic input LI4 genns caj na Not assigned T i L 1A Forced freewheel stop T L L LE External fault T L iH Motor preheating T L m Force to local control mode Can be Qo L TT Inhibits all protection selected T L E Reset motor thermal fault L E Activation of the cascade function T L Reset faults I Tye Activation of second set of motor parameters Preheatinglevel 4 4 i if preheating is selected L Pr j Parameters are visible if Time delay before preheating EON LIH is assigned 0 to 999 s To Assignment of logic output LO1 Lg j J
99. s start and deceleration of two different motors one after the other or one motor with two different configurations using a single soft starter e LIH motor preheating This selection does not appear if the CSC parameter in the drC menu is set to On It is used to prevent the motor from freezing or to prevent temperature deviations which may cause condensation If the input is active once the motor has stopped an adjustable current IPr flows through motor after an adjustable time delay tPr This current heats the motor without causing it to rotate IPr and tbr must be adjusted see below Speed RUN LI IPr current e Mon tPr When the input activates and the motor has stopped and after time delays tPr and tbS PrO menu have elapsed preheating starts Preheating stops if the input deactivates if a run command is sent or if the STOP input activates Lll inhibits all protection NOTE Use of this function invalidates the soft starter warranty This is meant to be used to override the soft starter in the event of an emergency smoke extraction system for example Preheating level 0 to 100 0 This parameter appears after LI3 or LI4 have been assigned to function LIH motor IF r preheating It is used to set the preheating current Use a true value current reading ammeter to set the current level Parameter ly has no effect on the IPr current Time delay before preheating 0 to 999 mn 5mn ib e This parameter appears a
100. since the last reset Active power as a percent Motor torque as a percent Active power in kW Display of the current state ACC rUn dEC etc Last fault detected Phase rotation direction 1 2 3 or 3 2 1 Keypad display locking code r E ojzTioiTono S Ol IO ala Set Uln in the drC menu a a amp le e e e 2 0 gt 0 lellei amp m amp v Gj L Parameters 58 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming The parameters in the SUP menu below can be modified with the motor stopped or running The factory setting displays the motor current parameter LCr To save the chosen display e Press the ENT key once the choice is temporary it will be cleared at the next power up e Press the ENT key again for 2 seconds the display flashes the choice is permanent and cannot be modified Table 25 Parameter Displayed Menu SUP Parameters Code cos Parameter Power Factor Unit 0 01 EHr Motor thermal state varies from 0 to 125 100 corresponds to the nominal thermal state for the current Iy set 96 Lir Motor current In amperes up to 999 A examples 01 5 is 1 5 A 15 0 is 15 A 150 is 150 A In kiloamperes starting at 1000 A examples 1 50 is 1
101. splay Mounting kit containing cover screws and an IP54 seal on the VW3G48101 front panel e 9 8ft 3 m cable with a 9 way SUB D connector for keypad display and an RJ 45 connector for connecting to an ATS48 controller Table 36 Protective Covers for Power Terminals LA9F702 Set of six protective covers for ATS48C14Y to ATS48C17Y Set of six protective covers for ATS48C21Y ATS48C25Y and LA9F703 ATS48C32Y NOTE The ATS48 controller has 9 unprotected power terminals PowerSuite Advanced Dialogue PowerSuite solutions are compatible with software version 1 30 build 5 Solutions Table 37 Pocket PC PDA Kits VW3A8108EN English VW3A8108FR French VW3A8108SP Spanish Complete PowerSuite Pak includes e Palm size HP JORNADA 525 Palm size PC terminal with operating system PC synchronization cable and power supply PowerSuite CD ROM setup software VW3A8014 Connection cable VW3A8111 Pocket PC PDA setup kit includes e CD ROM containing setup software Visas 102 e Connection kit for the Palm size PC terminal Available in English French and Spanish operating systems Cable connection kit for the Palm size PC terminal to an ATS48 controller includes VW3A8111 e 2 connection cables 9 8 ft 3 m each with two RJ 45 connectors e 1 RJ 45 9 way SUB D adaptor e 1 converter marked RS 232 RS 485 PPC with one 9 way male SUB D connector and 1 RJ 45 connector Table 38 P
102. stop type b Braking is active up to 20 of the nominal speed The total stop ramp depends on the setting of this parameter and also dependent on the motor loading See EbA below Motor speed 0 96 brC 0 brt brC 100 gt 0 96 0 T1 JL 12 INTELE djustment of motor braking time stop by EbA Impulse brake injection time T2 T1 x EbA NOTE Time T1 is not determined by brC T1 is the time required in seconds for the motor to fall from 100 of the nominal speed to 20 depends on the motor and application characteristics Injection time at the end of braking 20 to 100 20 This parameter can only be accessed if StY is set to b Selects adjustment of the current injection time at the end of braking for stop type b Can be set at 20 to 100 of the INTELE braking time T1 Example EbA INTELE braking 10 s T1 The stopping time can vary from 2 to 10 s T2 EbA 20 Corresponds to an injection time of 2 s EbA 100 Corresponds to an injection time of 10 s Factory setting 20 43 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming Figure 26 44 Protection Menu PrO Motor thermal protection Phase loss threshold Automatic restart Reset thermal state P Activation of motor monitoring by PTC probes PE H Protection classes 10 20 etc EHP
103. torque control 40 10 to 50 Add Starter address 0 0 to 31 Ebr Communication speed 19 2 4 8 9 6 19 2 c 2 801 8 bits odd 1 stop bit Eg 8E1 8 bits even 1 stop bit oo icati j i E E FOr Communication format 8n1 8n1 8 bits no parity 1 stop bit 5 E 8n2 8 bits no parity 2 stop bit u o ELP Serial link timeout setting 5 0 1 to 60s Configuration of serial link for PLE communications with remote keypad OFF On OFF display 72 2002 Schneider Electric All Rights Reserved This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 30072 450 61 06 2002 ALTISTART 48 Y Range Soft Start Controllers Appendix A Recommended Wiring Diagrams APPENDIX A RECOMMENDED WIRING DIAGRAMS Figures 33 35 illustrate circuit diagrams for typical non reversing and reversing applications in 2 wire and 3 wire control The recommended circuit diagrams include SCR fault isolation for optimal protection of the motor driven machinery and operating personnel Table 31 Description of Logic for Recommended Wiring Diagrams Item Name Description The isolation contactor logic closes IC1 upon a start command and opens IC1 after the stop is complete The RCR IC1 or RFR and RRR for reversing are timed contacts that must have a time delay greater than the deceleration ramp Isolation Contactor Fwd time or the INTELE braking time When a coast stop is selected the tim
104. ts below for the indication of these faults and the restart instructions MANUAL RESET FAULTS When a manual reset fault appears the soft starter locks and the motor switches to freewheel mode The following are signals that a manual reset fault has occurred e Relay R2 opens e Relay R1 opens e The fault code flashes on the display as long as the fault is present The last 5 faults are stored and viewable with the PowerSuite software workshop Perform the following steps before restarting the soft starter e Remove cause of the fault e In 2 wire and 3 wire control initiate a new run command rising edge on the RUN input to reset the fault NOTE A reset will not take place on a run command if LI is assigned to the fault reset LIr function e n2 wire and 3 wire control initiate another new run command rising edge on the RUN input to reset the fault 2002 Schneider Electric All Rights Reserved 65 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 8 Fault Management Table 30 Manual Reset Fault Correction Fault Displayed SLF Probable Cause Serial link fault 30072 450 61 06 2002 Corrective Action Check the RS 485 connection EEF External fault Check the custom fault Check the mechanism for wear mechanical play lubrication blockages etc Check the value of the tLs setting in the PrO
105. ument provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 7 Programming NOTE Shaded rows indicate typically locked out features 30072 450 61 06 2002 Refer to Table 18 for soft starter status codes Table 18 Soft Starter Status Codes Status Code Condition Fault code Faulty soft starter Soft starter without run command and nLP e Power not supplied rdY e Power supplied tbS Starting time delay not elapsed HEA Motor heating in progress Monitoring parameter selected by the user SUP menu Factory setting motor current Soft starter with run command brL Soft starter braking Stb Waiting for a command RUN or STOP in cascade mode Figure 25 Settings Menu When the current limit is applied to the soft Current limit as a percentage of ly ILE starter the displayed value flashes It is still possible to modify the parameters even if a A fault occurs on the soft starter Nominal motor current Acceleration ramp time Initial starting torque LAL Deceleration INTELE Freewheel o pump Braking Type of stop d h H F JEL LLL Parameters First level parameter settings Second level parameters depend upon choice of first level parameters To access the parameters see Figure 24 on page 39 40 2002 S
106. w barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 8 Fault Management 68 ALTISTART 48 TROUBLESHOOTING SHEET When requesting after sales service it is important to disclose all conditions under which the Square D Schneider Electric equipment currently operates This will help in diagnosing the system quickly FAX to Technical Support 919 217 6508 DATE CONTACT NAME COMPANY ADDRESS CITY STATE PHONE FAX SOFT START CONFIGURATION PART NUMBER ATS48 SERIAL NUMBER 6W APPLICATION EQUIPMENT DESIGNATION 30072 450 61 MOTOR NAMEPLATE DATA HORSEPOWER SERVICE FACTOR MOTOR CABLE TYPE VOLTAGE 3 PHASE FREQUENCY POLES FLA MOTOR TYPE DESIGN L NEMA A NEMAB _ NEVAC NEMAD POWER SOURCE AND ENVIRONMENT VOLTAGE BETWEEN L1 AND L2 SERVICE TRANSFORMER RATING KVA AMBIENT TEMPERATURES MIN C F APPROXIMATE CABLE LENGTH IN FEET VOLTAGE BETWEEN L2 AND L3 VOLTAGE BETWEEN L3 AND L 1 96 Z FREQUENCY 60Hz or L 50 Hz MAX C F HUMIDITY ALTITUDE IF GREATER THAN 3300 FEET ABOVE SEA LEVEL SPECIFY SOFT START FAULT CODES REFER TO TABLES 28 THROUGH 33 FOR POSSIBLE CAUSES amp CORRECTIVE ACTION FT NON RESET FAULTS AUTO RESET FAULTS CUSTOMER CONFIGURABLE MANUAL RESET FAULTS L OLF MOTOR THERMAL FAULT L INF INTERNAL FAULT LI PHF Loss OF PHASE OR LOSS OF MOTOR PHASE LI SLF SERIAL
107. y for 12 seconds or 300 of Iy for 23 seconds with a load factor of 50 and 10 starts per hour or an equivalent thermal cycling The motor thermal protection conforms to Class 10 overload protection In severe duty applications the ATS48 soft starter is designed to provide Starting at 400 of Iy for 48 seconds or 300 of Iy for 90 seconds from a cold state e Starting at 400 of Iy for 25 seconds with a load factor of 50 and 5 starts per hour or an equivalent thermal cycling The motor thermal protection conforms to Class 20 thermal overload protection The key to applying a soft start successfully is matching the load to the motor capability while starting with reduced voltage applied The asynchronous motor associated with the ATS48 soft starter must be able to accelerate the driven load when supplied with reduced voltage and current When reduced voltage is applied to a motor during acceleration the current the motor draws is reduced by the ratio of the voltage applied The torque produced by the motor varies with the square of the voltage at a fixed frequency Figure 17 on page 32 shows the speed torque characteristics as a function of the supply voltage 31 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com ALTISTART 48 Y Range Soft Start Controllers Section 6 Application and Protection INTELE Braking 32 30072 450 61 06 2002 Figure 17 Torque as

Altistart 48 Installation Guide - Barr

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