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Download SAFETY METHOD STATEMENT SE00175 11/12/03
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Transition Manual Migration from ATS46 to ATS48 Reasons for Change The ATS46 has been replaced by the ATS48, launched in August 2002.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. 874002567 Page 1 of 5 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. 874002567 Page 2 of 5 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 874002567 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 Page 3 of 5 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 874002567 Page 4 of 5 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 874002567 Page 5 of 5 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