Product Overview

The Schneider Electric ATS48C32Y Altistart 48 Soft Starter is an industrial motor starting and stopping device designed for three-phase asynchronous motors. It belongs to Schneider Electric’s Altistart 48 product family and is intended for applications requiring controlled motor acceleration, reduced starting stress, and managed deceleration.

When a conventional motor starter switches a motor directly onto the power supply, the motor can draw a high starting current and generate substantial mechanical shock. A soft starter addresses these conditions by controlling the voltage supplied to the motor during startup. This allows the motor to accelerate more progressively and helps reduce stress on electrical and mechanical equipment.

The ATS48C32Y supports torque-controlled starting and stopping. Its operating voltage range is 208–690 V AC, making it suitable for a range of industrial power systems. The product is designed for standard and severe-duty applications, including pumping and ventilation machinery.

The model is rated at 302 A in its product designation and documentation. Its motor power capability varies according to supply voltage and application duty. For example, the published ratings include 160 kW at 400 V for standard-duty applications and 132 kW at 400 V for severe-duty applications. Correct selection must therefore consider motor current, starting conditions, operating cycles, and the actual load.

The ATS48C32Y also provides motor and starter protection functions, programmable control inputs and outputs, and Modbus serial communication. These features allow it to operate as part of a larger industrial automation system.

Technical Specifications

Note: Motor power and current ratings depend on supply voltage and standard-duty or severe-duty operating conditions. Always use the manufacturer’s selection tables for the specific motor and application.

Function and Working Principle

The ATS48C32Y controls motor starting and stopping through semiconductor switching technology. It regulates the voltage supplied to the motor during the starting and stopping sequences, allowing the machine to accelerate and decelerate more smoothly than with direct-on-line starting.

1. Soft Starting

During startup, the soft starter gradually increases the voltage supplied to the motor. This helps control the motor’s acceleration and reduces the abrupt electrical and mechanical effects associated with direct starting.

The starting parameters can be adjusted to suit the motor and driven equipment. This is particularly useful for machines that experience frequent starts or operate under significant mechanical loads.

2. Torque Control

The Altistart 48 uses torque control to manage motor acceleration. Rather than relying only on a simple voltage ramp, the control strategy aims to provide a more appropriate torque response during startup.

This is useful in applications where sudden torque changes may cause mechanical shock, product movement, or excessive stress on transmission components.

3. Soft Stopping

The ATS48C32Y can also control motor deceleration. A controlled stopping process is valuable in applications where abrupt stopping may create pressure changes, material movement, or mechanical stress.

For example, in certain pumping systems, controlled deceleration can help reduce the risk of hydraulic shock. The appropriate stopping method and settings depend on the system design and process characteristics.

4. Current Limiting

Motor starting current can be substantially higher than normal running current. The soft starter provides current-limiting functions to help manage this demand during acceleration.

The ATS48 documentation specifies torque-controlled starting with current limited to 5 times the motor rated current under the stated operating conditions. Actual starting performance depends on motor characteristics, load torque, and configuration.

5. Motor and Starter Thermal Protection

The ATS48C32Y includes motor thermal protection and starter thermal protection. These functions help monitor operating conditions and protect equipment against thermal stress.

Correct motor data and protection settings are essential. The soft starter should not be treated as a replacement for all upstream electrical protection or the machine’s independent safety systems.

Role in Industrial Control Systems

The ATS48C32Y is commonly installed as part of an industrial motor-control circuit. It provides controlled starting and stopping while receiving commands from operators, PLCs, or other control equipment.

PLC Integration

A programmable logic controller can coordinate the soft starter with the rest of an automated machine. The PLC may issue run and stop commands, monitor operating status, and manage interlocks.

The ATS48C32Y provides discrete control connections and Modbus serial communication. This allows it to be integrated into suitable automation architectures, subject to the system’s communication and wiring requirements.

HMI Monitoring

A human-machine interface can provide operators with access to motor-control information, alarms, and operating status.

Depending on the control architecture, the HMI may communicate with the PLC, which exchanges information with the ATS48C32Y. This arrangement allows motor operation to be coordinated with other production equipment.

Motor Protection Coordination

The soft starter’s thermal protection functions form part of the motor-control strategy. They should be coordinated with upstream circuit protection, motor protection devices, and the machine’s emergency-stop and safety circuits.

Proper coordination helps prevent unnecessary shutdowns while maintaining suitable protection for the motor and starter.

Industrial Communication

The ATS48C32Y supports Modbus serial communication through an RS-485 interface. This can be used to exchange supported operating and diagnostic information with a compatible PLC or supervisory control system.

Communication parameters, wiring, addressing, and supported data registers should be checked during system integration.

Industrial Applications

The Altistart 48 series is designed for industrial applications involving three-phase asynchronous motors. The ATS48C32Y is particularly relevant to applications requiring substantial motor starting current and controlled acceleration.

1. Industrial Pumping Systems

Pumps are common applications for soft starters. Direct starting can create high starting current and sudden changes in hydraulic conditions.

The ATS48C32Y can provide controlled acceleration and stopping, helping reduce mechanical and hydraulic stress when correctly configured.

Typical applications include:

• Industrial water supply systems
• Process water circulation
• Water treatment equipment
• Industrial transfer pumps
• Cooling-water systems

2. Ventilation and Fan Systems

Large ventilation equipment often uses motors that benefit from controlled startup. A soft starter can help reduce the mechanical shock associated with starting large fan assemblies.

The ATS48C32Y can be incorporated into ventilation and air-handling systems where its electrical ratings match the motor and operating conditions.

3. Industrial Compressors

Compressor motors may experience significant starting loads, depending on compressor design and operating conditions.

A soft starter can help manage motor acceleration and starting current. The compressor’s unloading arrangement, starting torque, restart frequency, and operating sequence must be considered during equipment selection.

4. Conveyor Systems

Industrial conveyors often require controlled motor startup to reduce sudden tension changes in belts, chains, and mechanical couplings.

The ATS48C32Y can support controlled acceleration for suitable conveyor motors, helping coordinate material movement with upstream and downstream machinery.

5. Heavy Industrial Machinery

The Altistart 48 series is intended for standard and severe-duty motor applications. It may be used in industrial equipment where controlled starting and stopping are important to mechanical reliability and process continuity.

The motor’s power, current, duty cycle, and starting frequency must be evaluated before selecting the device.

Installation and System Integration

Correct installation is essential for safe operation and reliable motor control.

1. Verify the Electrical Supply

Confirm that the supply voltage falls within the specified 208–690 V AC range and that the supply frequency is compatible with the device.

The control circuit also requires a suitable 110–230 V AC control supply. Do not confuse the motor power supply rating with the control supply rating.

2. Select the Correct Motor Rating

The ATS48C32Y has different motor power ratings for standard-duty and severe-duty applications. At 400 V, for example, the published ratings are 160 kW for standard duty and 132 kW for severe duty.

The correct selection should be based on motor nameplate current, operating voltage, starting conditions, load torque, and expected starts per hour.

A motor’s kilowatt rating alone is not sufficient to establish compatibility.

3. Mounting and Panel Installation

The supplied dimensions are 380 × 320 × 265 mm, and the listed weight is 18.2 kg.

The unit should be mounted in a suitable electrical cabinet with adequate space for wiring, maintenance, and heat dissipation. Follow the manufacturer’s mounting orientation and clearance requirements.

The ATS48C32Y has an IP00 protection rating. It does not provide a complete protective enclosure against dust, water, or accidental contact. A suitable cabinet and appropriate installation safeguards are therefore necessary.

4. Power Wiring

Connect the incoming supply and motor conductors according to the manufacturer’s wiring diagrams. Use conductors and protective devices rated for the application.

Grounding must comply with applicable electrical standards. Power cables and control cables should be routed appropriately to reduce electromagnetic interference.

All installation and maintenance work should be performed by qualified personnel after the equipment has been isolated and verified safe.

5. Configure Starting and Stopping Parameters

Set the starting torque, current limit, acceleration characteristics, and stopping parameters according to the motor and mechanical load.

Incorrect settings may lead to excessive starting time, insufficient acceleration torque, or unwanted protective trips.

Commissioning should include testing under actual operating conditions rather than relying only on unloaded motor tests.

6. PLC and Modbus Integration

When integrating the ATS48C32Y with a PLC, confirm the control input assignments, output functions, Modbus communication settings, and signal references.

Test the start and stop commands, fault indications, operating status, and communication response before putting the machine into normal production.

7. Thermal Management

Soft starters generate heat during operation, particularly during starting and under demanding duty conditions. The electrical cabinet must provide adequate ventilation and heat dissipation.

The manufacturer specifies power dissipation values according to operating conditions. These should be considered when calculating the cabinet’s thermal requirements.

Compatible System Components

The ATS48C32Y is normally used with other electrical and automation components to form a complete motor-control installation.

The components listed above are examples of equipment used in a complete installation. They are not necessarily included with the ATS48C32Y.

Alternative Models and Replacement Considerations

The Schneider Electric ATS48C32Y has been discontinued. Schneider Electric identifies the ATS480C32Y Altistart 480 as its recommended replacement.

When replacing the ATS48C32Y, engineers should compare:

• Supply voltage and frequency.
• Motor rated current and power.
• Standard-duty or severe-duty classification.
• Starting torque and current-limit requirements.
• Acceleration and deceleration settings.
• Control supply voltage.
• PLC I/O assignments.
• Modbus communication requirements.
• Mounting dimensions and cabinet clearances.
• Thermal management and protection coordination.

The ATS480C32Y is the manufacturer’s recommended replacement, but it should not be assumed to be a plug-and-play substitute in every installation. Wiring, parameter settings, communication configuration, and commissioning procedures may need to be updated.

Key Advantages

Controlled Motor Starting

The ATS48C32Y regulates motor acceleration to help reduce the electrical and mechanical stress associated with direct-on-line starting.

Torque-Controlled Operation

Its torque-control starting method provides a more controlled motor acceleration strategy for suitable industrial loads.

Controlled Stopping

Soft stopping can help reduce abrupt mechanical changes and support smoother process shutdowns.

Integrated Motor Protection

Built-in thermal protection functions help monitor motor and starter operating conditions.

Industrial Communication

Modbus serial communication supports integration with compatible PLCs and industrial control systems.

Broad Voltage Compatibility

The 208–690 V AC supply range supports use in a variety of industrial power systems, provided the motor and application ratings are appropriate.

Heavy-Duty Application Capability

The Altistart 48 family is designed for standard and severe-duty applications, including pumps, ventilation equipment, and industrial machinery.

Technical FAQs

1. What is the Schneider ATS48C32Y?

The ATS48C32Y is an Altistart 48 soft starter designed to control the starting and stopping of three-phase asynchronous motors.

2. What is the rated voltage range?

Its rated supply voltage range is 208–690 V AC, with a specified tolerance of -15% to +10%.

3. What is the rated current?

The product documentation identifies the ATS48C32Y as a 302 A soft starter. Application selection must also consider the applicable starter rating and duty classification.

4. What motor power can it support?

At 400 V, the published motor power ratings are 160 kW for standard-duty applications and 132 kW for severe-duty applications. The applicable rating changes with voltage and duty conditions.

5. What is the difference between a soft starter and a variable frequency drive?

A soft starter primarily controls motor voltage during starting and stopping. A variable frequency drive controls motor speed during normal operation by adjusting output frequency and voltage.

The ATS48C32Y is designed primarily for controlled starting and stopping rather than continuous variable-speed regulation.

6. Does the ATS48C32Y support PLC communication?

Yes. It supports Modbus serial communication through an RS-485 interface. The PLC and communication settings must be configured correctly.

7. Is motor protection included?

The ATS48C32Y includes motor thermal protection and starter thermal protection. These functions should be coordinated with the complete electrical protection design.

8. What is the protection rating?

The ATS48C32Y has an IP00 protection rating. It must be installed in an appropriate electrical enclosure that provides the protection required by the installation environment.

9. Is the ATS48C32Y still manufactured?

Schneider Electric discontinued commercial sales of the ATS48C32Y on August 7, 2023. The manufacturer lists the ATS480C32Y as the recommended replacement.

10. What should be checked before purchasing a replacement?

Verify the complete model number, voltage rating, current rating, motor power, duty classification, control supply, communication requirements, physical condition, and included accessories.

Procurement and Maintenance Recommendations

The ATS48C32Y is a discontinued industrial soft starter, so procurement should begin with accurate model identification and a review of the original installation requirements.

When sourcing this model, confirm that the nameplate matches ATS48C32Y. Check the rated voltage, current, duty classification, control supply, and communication configuration. If purchasing used or refurbished equipment, request clear photographs of the terminals, nameplate, and enclosure, along with available functional test information.

For critical production equipment, confirm the supplier’s warranty, return conditions, and testing arrangements before purchase. Also verify the shipping dimensions and weight separately if the unit is being transported internationally.

During maintenance, inspect the power connections, control terminals, cabinet ventilation, and signs of overheating. Check that the motor and starter protection settings remain appropriate for the application.

If the ATS48C32Y is being replaced with an ATS480C32Y, review the wiring diagrams, control interface, communication settings, and commissioning procedure. A replacement project should include functional testing of the complete motor-control system before the machine returns to production.

Conclusion

The Schneider Electric ATS48C32Y Altistart 48 Soft Starter is designed for controlled starting and stopping of three-phase asynchronous motors in industrial applications. With a 208–690 V AC supply range, a published 302 A rating, torque-controlled starting, integrated thermal protection, and Modbus serial communication, it can be incorporated into a wide range of suitable motor-control systems.

Its application ratings vary according to supply voltage and duty classification, so careful motor selection is essential. Since the ATS48C32Y has been discontinued, maintenance teams and procurement specialists should verify the exact configuration and consider the manufacturer-recommended ATS480C32Y when planning replacement projects.