Product Overview

The Schneider ATS22C59S6 is a high-capacity Altistart 22 soft starter designed for controlled starting and stopping of three-phase asynchronous motors in demanding industrial applications. It is intended for large motor-driven equipment where direct-on-line starting may create excessive current, mechanical shock, and unnecessary stress on electrical and mechanical systems.

Large motors can require several times their normal operating current during direct starting. This high starting current can affect electrical distribution systems, particularly when several high-power motors operate within the same facility. At the mechanical level, the sudden application of motor torque can also place considerable stress on shafts, couplings, gearboxes, belts, pumps, fans, compressors, and conveyor systems.

The ATS22C59S6 provides a controlled motor-starting process that allows acceleration to take place progressively. This can help reduce the electrical and mechanical impact associated with conventional direct-on-line motor starting.

As a member of the Schneider Altistart 22 family, the ATS22C59S6 is designed for industrial motor-control applications where reliable starting performance is more important than continuous variable-speed operation. Unlike a variable frequency drive, the soft starter is primarily intended to manage motor acceleration and deceleration rather than provide continuous speed regulation.

The ATS22C59S6 belongs to a higher-current class within the ATS22 family and is suitable for large industrial motors when the motor’s rated current and application duty are compatible with the starter’s characteristics.

The supplied physical dimensions of the Schneider ATS22C59S6 are approximately 455 × 304 × 339.7 mm, and the supplied weight is approximately 50 kg. These relatively large dimensions and weight should be considered carefully when designing the electrical cabinet, mounting structure, ventilation system, cable routing, and maintenance access.

Technical Specifications

What Is the Schneider ATS22C59S6?

The Schneider ATS22C59S6 is a high-current industrial soft starter used to control the starting and stopping of compatible three-phase asynchronous motors.

Its primary purpose is to provide a controlled transition between a stopped motor and normal operating speed. During direct-on-line starting, a motor can draw a very high current and generate a rapid increase in torque. For large motors, this can place significant stress on the electrical power system and connected mechanical equipment.

The ATS22C59S6 manages the starting sequence to make motor acceleration more progressive. This can be particularly valuable in industrial machinery where sudden acceleration could cause belt slippage, coupling stress, gearbox loading, hydraulic shock, or excessive vibration.

For electrical systems, controlled starting can also help limit the magnitude of starting current. This can be important in facilities where large motors share a common power distribution system.

The ATS22C59S6 should not be confused with a variable frequency drive. A VFD changes motor frequency and voltage continuously to control motor speed. A soft starter such as the ATS22C59S6 is primarily designed to control the starting and stopping process while allowing the motor to operate at normal line frequency during normal operation.

Function and Working Principle

The basic motor-control arrangement can be represented as:

Three-Phase Power Supply → Protection Equipment → ATS22C59S6 → Three-Phase Motor → Mechanical Load

When a start command is applied, the ATS22C59S6 begins its programmed starting sequence. Instead of allowing the motor to immediately experience the full impact of direct-on-line starting, the soft starter controls the electrical conditions during acceleration.

The Altistart 22 architecture uses torque-controlled starting together with current limitation. The starting current can be limited to approximately 3.5 times the configured motor current, depending on the operating configuration and application conditions.

This controlled acceleration allows the motor to build speed progressively. The exact acceleration behavior depends on the motor characteristics, connected load, configured parameters, and installation conditions.

Once the motor reaches its normal running condition, the internal bypass function can provide a direct operating path. This helps reduce losses associated with the semiconductor power-control stage during normal motor operation.

The ATS22C59S6 can also provide controlled stopping for applications where a gradual reduction in motor operation is beneficial. The stopping behavior should be selected according to the mechanical and process requirements of the machine.

In addition to local control functions, the soft starter can be integrated into an industrial automation system through its communication interface. Modbus communication over RS485 can be used for monitoring, control, diagnostics, and data exchange with compatible automation equipment.

Motor Power Application

The ATS22C59S6 is intended for high-current motor applications. Actual motor power capability varies according to supply voltage, motor efficiency, power factor, operating duty, and application conditions.

These application categories are provided as general selection guidance. The actual soft starter selection should always be based on the motor nameplate current and the required starting duty rather than relying only on motor horsepower or kilowatt rating.

Role in Industrial Control Systems

The ATS22C59S6 can be used as the motor-starting component within a larger industrial control system. It can operate together with PLCs, HMIs, circuit breakers, contactors, sensors, and industrial communication networks.

A typical control architecture may contain:

• PLC controller
• HMI operator interface
• ATS22C59S6 soft starter
• Three-phase asynchronous motor
• Incoming circuit breaker
• Motor protection equipment
• Isolation or switching contactor
• Emergency stop circuit
• Process sensors
• Modbus RS485 communication network
• Industrial control power supply

The PLC can manage the machine sequence and determine when the motor should operate, while the ATS22C59S6 controls the motor’s acceleration and stopping behavior.

For example, in a large industrial pump station, a PLC may monitor pressure and flow sensors. When the process requires additional pumping capacity, the PLC can issue a start command to the soft starter. The ATS22C59S6 then controls the motor acceleration, while status and fault information can be returned to the automation system.

This architecture provides a clear separation between process control and motor-starting functions.

Industrial Applications

Large Pumping Systems

Large pumps can have considerable motor power and hydraulic inertia. Direct-on-line starting may create significant current demand and mechanical or hydraulic stress. A soft starter can provide a more controlled acceleration sequence.

Applications can include industrial water systems, process pumping, cooling-water systems, wastewater equipment, and other large pump installations.

Industrial Fans and Blowers

Large fans and blowers often have high rotational inertia. The ATS22C59S6 can be considered for applications where the fan motor requires controlled acceleration without continuous variable-speed operation.

Heavy-Duty Conveyors

Long conveyors and heavy material-handling systems can place considerable mechanical loads on belts, gearboxes, shafts, and couplings during startup. Controlled acceleration can help reduce the sudden torque transferred through the mechanical system.

Compressors

Large compressors can require high starting current. A correctly sized soft starter can help manage the motor starting process while allowing normal line-frequency operation once the motor has reached its running condition.

Industrial Process Equipment

Large mixers, agitators, crushers, blowers, and other process machines can benefit from controlled starting when the application does not require continuous speed adjustment.

Mining and Material Processing

Heavy industrial machinery used in mining and material processing can contain high-inertia mechanical systems and large motors. A high-current soft starter can be integrated into suitable motor-control systems to improve starting behavior.

HVAC and Utility Equipment

Large ventilation systems, cooling equipment, pumps, and utility machinery may use high-power motors. The ATS22C59S6 can provide controlled starting where the motor and application requirements fall within its electrical and thermal capabilities.

Installation and System Integration

Correct installation is important for the reliable operation of a high-current soft starter. The ATS22C59S6 should be selected according to the motor’s electrical characteristics, application duty, environmental conditions, and control requirements.

Verify Motor Nameplate Information

Before installation, verify the motor’s rated voltage, full-load current, frequency, power rating, connection configuration, and operating duty. The motor’s rated current is especially important when determining soft starter compatibility.

Verify the Incoming Power

The ATS22C59S6 is designed for three-phase AC motor supply applications within the applicable ATS22 voltage range. The actual installation voltage should be verified before energization.

Check the Control Circuit

The S6 version uses a 230 V AC control circuit. The control voltage should be verified carefully before wiring the control terminals.

Electrical Protection

Appropriate upstream circuit protection, isolation equipment, and motor protection should be included in the complete installation. Protection must be selected according to the motor, starter, electrical system, and applicable installation requirements.

Mechanical Mounting

The supplied ATS22C59S6 dimensions are approximately 455 × 304 × 339.7 mm, with a supplied weight of approximately 50 kg.

Because of its size and weight, the mounting structure should provide adequate mechanical support. Cabinet designers should also allow sufficient space for power cables, control wiring, airflow, inspection, and maintenance.

Cooling and Ventilation

The ATS22C59S6 uses forced-convection cooling. The cabinet should therefore provide suitable airflow around the equipment and prevent excessive heat accumulation.

When multiple power devices are installed in the same cabinet, their combined heat dissipation should be considered during thermal design.

Motor Connection

Motor power connections should be inspected carefully before energization. Phase sequence, terminal connections, cable sizing, grounding, and connection tightness should be verified during commissioning.

Control and Communication

The soft starter can be connected to a PLC or other control system through its logic inputs, relay outputs, and communication interface. If Modbus RS485 is used, the communication address and network parameters should be configured consistently with the master device.

Commissioning

Initial commissioning should include checking the control voltage, incoming supply, motor connection, motor rotation direction, acceleration behavior, stopping behavior, current response, fault status, and communication status.

Testing should initially be performed under controlled operating conditions before the equipment is returned to full production.

Compatible System Components

Recommended Alternative Models

When replacing or upgrading an ATS22C59S6, engineers should compare the complete model number, current rating, control voltage, supply voltage, application duty, mounting dimensions, and communication requirements.

A model with a similar physical appearance is not necessarily an electrically equivalent replacement. The motor’s full-load current and starting duty should always be checked before selecting an alternative.

Key Advantages

• Designed for large three-phase asynchronous motors
• Part of the Schneider Altistart 22 soft starter family
• High-current 590 A class starter
• 230 V AC control circuit
• Designed for industrial motor starting and stopping
• Torque-controlled starting
• Starting current limitation of approximately 3.5 × In
• Internal bypass function
• Modbus communication capability
• RS485 industrial communication interface
• Three logic inputs and two relay outputs
• PTC probe input
• Forced-convection cooling
• Suitable for PLC-based motor-control systems
• Suitable for large pumps, fans, compressors, conveyors, and process equipment
• Large physical construction suitable for high-power motor applications
• Supplied dimensions of approximately 455 × 304 × 339.7 mm
• Supplied weight of approximately 50 kg

Technical FAQs

What is the Schneider ATS22C59S6?

The Schneider ATS22C59S6 is a high-current Altistart 22 soft starter designed for controlled starting and stopping of three-phase asynchronous motors.

What is the main function of the ATS22C59S6?

Its main function is to control motor acceleration and stopping, helping reduce the electrical and mechanical stresses associated with direct-on-line motor starting.

What is the current rating of the ATS22C59S6?

The ATS22C59S6 belongs to the 590 A starter class, making it suitable for large industrial motor applications when correctly matched to the motor’s rated current and operating duty.

What control voltage does the ATS22C59S6 use?

The ATS22C59S6 S6 version uses a 230 V AC control circuit. The control voltage should be confirmed before installation.

What type of motor can the ATS22C59S6 control?

It is designed for compatible three-phase asynchronous motors. Motor voltage, current, power, starting duty, and load characteristics must be evaluated before selection.

Does the ATS22C59S6 support Modbus communication?

Yes. The Altistart 22 architecture supports Modbus communication through an RS485 interface for suitable monitoring and control applications.

Does the ATS22C59S6 have an internal bypass?

Yes. The ATS22C59S6 includes an internal bypass function that can be used after the motor reaches its normal running condition.

Can the ATS22C59S6 be connected to a PLC?

Yes. It can be integrated into a PLC-based control system using its logic inputs, relay outputs, and communication interface.

What applications are suitable for the ATS22C59S6?

Typical applications include large pumps, industrial fans, compressors, conveyors, mixers, material-handling equipment, process machinery, and other high-power motor-driven systems.

Is the ATS22C59S6 a variable frequency drive?

No. It is a soft starter. Its main purpose is controlled motor starting and stopping rather than continuous variable-frequency speed control.

What are the dimensions of the ATS22C59S6?

The supplied dimensions are approximately 455 × 304 × 339.7 mm.

How much does the ATS22C59S6 weigh?

The supplied product weight is approximately 50 kg.

What should be checked before replacing an ATS22C59S6?

Motor rated current, motor supply voltage, control voltage, starting duty, load inertia, electrical protection, cabinet dimensions, cooling requirements, control wiring, communication requirements, and mounting conditions should all be checked before selecting a replacement.

Conclusion

The Schneider ATS22C59S6 Soft Starter is a high-capacity industrial motor-control solution designed for large three-phase asynchronous motors. Its high-current design makes it suitable for demanding applications where direct-on-line starting could create excessive electrical current or mechanical stress.

With torque-controlled starting, current limitation, internal bypass, Modbus communication, and integration capabilities for PLC-based automation systems, the ATS22C59S6 can provide a practical solution for large industrial motor applications.

The model is particularly suitable for equipment such as large pumps, fans, compressors, conveyors, mixers, material-handling machinery, and industrial process equipment. Correct application depends on matching the soft starter to the motor’s rated current, supply voltage, starting duty, and mechanical load.

The supplied dimensions of approximately 455 × 304 × 339.7 mm and weight of approximately 50 kg are important considerations for cabinet and equipment design. Because this is a relatively large and heavy soft starter, the mounting structure, cable routing, ventilation, and maintenance access should be designed accordingly.

For electrical engineers, system integrators, OEM machine builders, and industrial maintenance teams, the ATS22C59S6 offers a controlled approach to starting large motors while maintaining compatibility with conventional industrial control architectures. When correctly selected, installed, configured, and maintained, it can help improve motor-starting performance and provide a reliable interface between high-power motor equipment and modern industrial automation systems.