Download SAFETY METHOD STATEMENT SE00175 11/12/03

Transition Manual
Migration from ATS46 to ATS48
Reasons for Change
The ATS46 has been replaced by the ATS48, launched in August 2002. Repair of existing
ATS46 models is available through Schneider Electric.
The ATS48 range includes all of the features of the ATS46 line (including torque control) with
the added benefits of reduced size, a 600V range and more communication options.
Objective
The objective of this work instruction is to guide the Technician responsible for changing an
ATS46 model to an ATS48 model in the most efficient manner.
Adapter plate
Due to the reduced size of the ATS48 model range, the existing panel holes will not line up
with the existing ATS46 footprint.
Schneider Electric has created adapter plates that allow the ATS to be changed without the
need for marking out new templates, drilling etc.
Line Power
There has been a change in the connection type. On the ATS48C14Y and above the
connection has been changed to a “lug” instead of a “screw” type. This will necessitate
adding a connection to the existing wiring. Line (feed) cables for ATS46 frame size 3 are
bottom entry. All ATS48 line connections are top entry. Re-routing of these cables will be
required.
Control Power
The ATS46 range was line voltage powered. The ATS48 requires a control voltage of 120
VAC.
This change was made to allow a technician to safely load parameters and check fault
messages without the need to have the high voltage applied. If 120 VAC is not available a
suitable step down transformer is required. The requirements are shown in Table 5 below.
Interposing Relay
The ATS46 had a fault relay that had both a N.O. & N.C. contacts.
The ATS48 has three configurable relays one of which can be used for fault signaling.
However, all three are N.O. only. If the application requires a N.C. signal a small interposing
relay is required. A suggested relay would be Schneider Electric part number CA3SK11BD if
coil voltage is 24 VDC, or part number CA2SK11G7 if using a 120 VAC coil voltage.
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Replacement Work Instructions
 If parameter settings are not recorded by other means, while power is still applied to the
soft start, inspect and record the parameters in Table 1 below.
 Ensure the Plant Maintenance Lock Out and Isolation Procedures are followed.
 Ensure electrical test equipment is proven by testing on a known supply.
 Check that all supplies to the ATS are isolated. (Mains supply voltage and control
voltage).
 Ensure the motor to be disconnected is stationary. (i.e. large fans are not still spinning
creating back EMF).
 Inspect and record the power & control wiring connection points on Table 2 below.
 Disconnect all wiring.
 Remove the ATS46 from the existing control panel mounting plate, saving the mounting
screws.
 Using the saved screws from above, mount the appropriate adapter plate, from Table 3
below.
 Bond the Adapter Plate to an existing earth point on the control panel.
 Fit the new ATS48 to the adapter plate using screws identified in Table 4 below.
 Using the ATS48 Manual and Table 2 as a guide, reconnect the power and control wiring.
 Load (motor) cables and control cables will be of sufficient length.
 Line (feed) cables will be of sufficient length for ATS46 frame size 1 & 2.
 Line (feed) cables for ATS46 frame size 3 (ATS46C17N to ATS46C32N) & frame size
4 (ATS46C41 to ATS46C66N) will need to be re-routed from bottom entry on the
ATS46 to top entry on the ATS48. If they will not reach the power input terminals, affix
a set of rail mounted, shrouded terminals to the mounting points provided, connect
from the terminals to the drive with short extension cables.
 Once it has been determined safe to do so, apply control voltage to the ATS48.
 Set the ATS48 software parameters to suit the machine operation, using the ATS48
manual and notes made on Table 1.
 Main power can now be reapplied and system tested to insure proper operation.
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Table 1
FORD Schematic Ref:
ATS46
Parameter
Description
Parameter
Level
Motor power factor
Cos
L1
Motor thermal state
Lth
L1
Active motor power
LPr
L1
Motor load state
Ltr
L1
Motor current
Lcr
L1
Starter state
rdy
L1
Motor nominal current (usually motor FLA)
In
L2
Motor limit current
ILt
L2
Acceleration torque ramp
Acc
L2
Stop type
Sty
L2
Deceleration torque ramp
dEc
L2
Threshold for freewheel at end of
Edc
L2
brc
bSt
t90
tLI
L2
L2
L2
L2
ULL
tLS
thP
ArS
CLP
LSc
0-4
LI
LoI
OIL
Phr
rI
rth
Int
EbA
Ao
ASc
SSt
CSc
tFr
tbS
L2
L2
L2
L3
L3
L3
L3
L3
L3
L3
L3
L3
L3
L3
L3
L3
L3
L3
L3
L3
L3
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deceleration ramp
Braking torque level
Voltage boost
Initial torque on starting
Limitation of maximum torque during
acceleration
Motor underload threshold
Start time to long
Motor thermal protection
Automatic reset
Torque control
Stator loss compensation
Configuration of AO1
Assignment of LI
Assignment of LO1
Current trip threshold
Detection of phase rotation
Assignment of relay R1
Reset of motor thermal state
Return to factory setting
Motor run down time adjustment
Assignment of analogue output AO1
Scaling of analogue output AO1
Test on low power motor
Cascade connection start
Operating time since reset (in seconds)
Time before restart
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Ford Setting
Factory
Setting
N/A
N/A
N/A
N/A
N/A
N/A
N/A
300%
10s
F
10s
20
50
oFF
10
oFF
oFF
oFF
10
oFF
on
50
20
LIA
tAI
oFF
oFF
rIF
no
no
20
Acr
200
oFF
oFF
2
Table 2
FORD Schematic Ref:
ATS46 WIRING
ATS46
CONNECTION
POINT REF.
1/L1
3/L2
5/L3
2/T1
4/T2
6/T3
C
230
400
STOP
RUN
LI
PL
LO+
LO1
FORD
SCHEMATIC
WIRING REF.
ATS48 WIRING
ATS48
CONNECTION
POINT REF.
1/L1
3/L2
5/L3
2/T1
4/T2
6/T3
CL1
CL2
STOP
RUN
LI3
LI4
+24V
LO+
LO1
LO2
LO2
AO1
AO1
COM
R1B
COM
PTC1
PTC2
-
R1D
-
R1A
R1C
R2A
R2C
-
R1A
R1C
R2A
R2C
R3A
R3C
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ATS
FUNCTION
Line Power
Line Power
Line Power
Load Power
Load Power
Load Power
Control Power Supply, Common ATS48
ATS46 only. Control Board 230V Supply.
Control Power Supply, 120 VAC ATS48
Logical Input 1. 0V Stop instruction
Logical Input 2. +24V run Instruction
Logical Input 3. Configurable
Logical Input 4. Configurable
Configurable. Factory = ‘LIA’ Freewheel
+24V supply from control board
Configurable Logical Output. Factory = ‘tAI’
Motor thermal fault (to COM)
Configurable Logical Output. Factory = XXX
(to COM)
Configurable Analogue Output 0-20mA, 420mA. Factory = 0-20mA
Common for LO1, LO2, AO1
Input for PTC probe
Input for PTC probe
ATS46 only. R1 Assignable N/C fault relay
contact
ATS46 only. R1 Assignable N/C fault relay
contact
R1 Configurable N/O Control Contact
R1 Configurable N/O Control Contact
R2 Configurable N/O Control Contact
R2 Configurable N/O Control Contact
R3 Configurable N/O Control Contact
R3 Configurable N/O Control Contact
Table 3
ATS 46 Model
Replaced by ATS48 Model
ATS46D17N
ATS46D22N
ATS46D32N
ATS46D38N
ATS46D62N
ATS46D75N
ATS46D88N
ATS46C11N
ATS46C14N
ATS46C17N
ATS46C21N
ATS46C25N
ATS46C32N
ATS46C41N
ATS48D17Y
ATS48D22Y
ATS48D32Y
ATS48D38Y
ATS48D62Y
ATS48D75Y
ATS48D88Y
ATS48C11Y
ATS48C14Y
ATS48C17Y
ATS48C21Y
ATS48C25Y
ATS48C32Y
ATS48C41Y
Frame
Size
1
1
1
1
2
2
2
2
3
3
4
4
4
5
Adapter Plate
Number
VX3GBA48821
VX3GBA48821
VX3GBA48821
VX3GBA48821
VX3GBA48822
VX3GBA48822
VX3GBA48822
VX3GBA48823
VX3GBA48824
VX3GBA48825
VX3GBA48825
VX3GBA48825
VX3GBA48825
N\A
Table 4
Model
ATS48 Frame size 1
ATS48 Frame size 2
ATS48 Frame size 3
ATS48 Frame size 4
ATS48 Frame size 5
All Frame sizes
Mounting Screws
4 of M6 X 10mm
4 of M6 X 10mm
4 of M6 X 10mm
4 of M8 X 10mm
1 of M6 Nut & Washer
Table 5
ATS48
ATS48D17Y to ATS48C17Y
ATS48C21Y to ATS48C32Y
ATS48C41Y to ATS48M12Y
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Input
Power
Required
30 W
50 W
96 W
Minimum
Transformer
Required
50 VA
100 VA
100 VA
Schneider Electric
Fusible Transformer
Part Number
9070TF100D1