Product Overview

The Schneider Electric ATS48C66Y Altistart 48 Soft Starter is a high-current motor starting and stopping device designed for three-phase asynchronous motors in demanding industrial applications. It belongs to the Altistart 48 product family and is intended to control motor acceleration and deceleration while reducing the electrical and mechanical stress associated with direct-on-line starting.

When a large motor starts directly across the power supply, it can draw a substantial starting current and generate sudden mechanical torque. These conditions may cause voltage fluctuations, mechanical shock, belt stress, pressure surges, and additional wear on connected equipment. A soft starter helps manage the motor’s starting process by controlling the voltage and torque applied during acceleration.

The ATS48C66Y supports a wide supply voltage range of 208–690 V AC and is designed for high-power applications. Its published factory current setting is 590 A, while its nominal soft-start current rating is 660 A for the specified in-line connection. Motor power capability varies according to supply voltage and duty classification, reaching up to 630 kW in certain standard-duty applications at 690 V.

The Altistart 48 uses torque-control technology to provide controlled motor starting and stopping. It also incorporates motor and starter protection functions, configurable logic inputs and outputs, and a communication interface for integration into industrial control systems.

The ATS48C66Y is a large industrial unit with a supplied product size of 670 × 400 × 300 mm and a weight of 51.4 kg. Its IP00 enclosure rating means it must be installed inside a suitable electrical cabinet or protected electrical installation.

Schneider Electric discontinued this model on August 7, 2023, and identifies ATS480C66Y from the Altivar ATS480 family as its recommended replacement. Existing ATS48C66Y units may still be relevant for maintenance and spare-parts requirements in installations using the Altistart 48 platform.

Technical Specifications

Motor Power Ratings

The maximum motor power depends on supply voltage and the selected duty classification.

Important: These are application-dependent ratings. Final selection must account for motor nameplate current, starting frequency, load inertia, ambient temperature, installation conditions, and the manufacturer’s duty-rating requirements.

Function and Working Principle

The ATS48C66Y controls the starting and stopping process of a three-phase asynchronous motor. Unlike a conventional contactor that connects the motor directly to the supply, a soft starter regulates the motor’s electrical input during the starting and stopping sequences.

1. Controlled Motor Starting

During startup, the ATS48C66Y progressively controls the voltage supplied to the motor. This helps manage the current drawn from the electrical network and reduces abrupt torque changes.

The controlled starting process can help protect mechanical components such as:

• Gearboxes and couplings.
• Conveyor belts and drive chains.
• Pump shafts and impellers.
• Fan assemblies.
• Compressors and mechanical transmission systems.

For large motors, controlled acceleration can also reduce the impact of starting current on the plant’s electrical distribution system.

2. Torque Control System

A key feature of the Altistart 48 series is its Torque Control System (TCS). Instead of relying only on a simple voltage ramp, the starter uses torque control to manage motor acceleration.

This approach is particularly useful in applications where mechanical loads require a controlled increase in torque. It can help reduce sudden movement during startup and improve the transition from standstill to normal operating speed.

The ATS48C66Y supports torque-controlled starting with current limited to approximately five times the configured nominal current under its specified operating conditions.

Actual starting performance depends on the motor characteristics, load inertia, parameter settings, and supply conditions.

3. Controlled Motor Stopping

The soft starter can also manage motor deceleration. Controlled stopping is useful when an application requires the motor to slow down progressively instead of stopping immediately after power disconnection.

For pump systems, controlled stopping may help reduce hydraulic pressure changes and water hammer. In conveyor systems, it can support a smoother transition between operating states.

The stopping method should be selected according to the process and mechanical characteristics of the equipment. A soft starter is not a substitute for a mechanical brake or a safety-rated stopping system where those devices are required.

4. Current Limitation

The ATS48C66Y includes current-limiting functionality to manage the electrical demand during motor startup.

Its current setting must be configured according to the motor nameplate and application requirements. The factory setting is 590 A, while the published nominal soft-start current rating is 660 A for the specified in-line connection.

Correct configuration is important for achieving the intended starting performance and motor protection.

5. Motor and Starter Protection

The Altistart 48 provides protection functions designed to monitor operating conditions and identify abnormal events.

These include functions related to motor thermal protection, starter thermal protection, and phase failure. The device also provides relay and logic outputs that can communicate operating states and fault conditions to a PLC or other control equipment.

Protection settings must be coordinated with the motor, upstream electrical protection, and overall machine safety design.

Role in Industrial Control Systems

The ATS48C66Y can serve as a motor-starting control device within a larger industrial automation system. It is normally installed in the motor power circuit and connected to a control system that manages machine operation.

PLC Integration

A programmable logic controller can coordinate the soft starter with sensors, contactors, process instruments, and other automation equipment.

The PLC can issue operating commands and monitor available status signals. The ATS48C66Y provides five discrete inputs, configurable logic outputs, and relay outputs for fault, starting-complete, and motor-powered indications.

These signals can be used in machine sequences, interlocking logic, and equipment status monitoring.

HMI Monitoring

A human-machine interface can display the motor’s operating state, starter status, alarms, and process information.

In a typical installation, the HMI communicates with the PLC or control network. Operators can use the interface to monitor startup sequences, identify abnormal conditions, and coordinate maintenance activities.

Modbus Communication

The Altistart 48 supports communication through its RJ45 Modbus interface. This allows the starter to exchange supported data with compatible control equipment.

Additional network integration may require an appropriate communication module or gateway, depending on the target network and system architecture.

Before designing the communication system, engineers should verify the supported protocol, communication parameters, hardware requirements, and device configuration.

Electrical Distribution Coordination

Because the ATS48C66Y is designed for high-current motor applications, it must be coordinated with the plant’s electrical distribution system.

The installation should account for:

• Incoming supply voltage and fault level.
• Motor rated current and starting characteristics.
• Upstream circuit breakers or fuses.
• Isolation and bypass arrangements.
• Cable sizing and thermal limits.
• Cabinet ventilation and heat dissipation.
• Grounding and electrical protection.

The complete installation should be designed and checked by qualified electrical engineering personnel.

Industrial Applications

The ATS48C66Y is intended for demanding industrial motor applications, including heavy-duty machinery and large pumping systems.

1. Industrial Pumping Systems

Large pumps are widely used in water treatment, industrial processing, utilities, and infrastructure facilities.

Direct starting can produce sudden pressure changes in the connected pipeline. The ATS48C66Y can provide controlled acceleration and deceleration to help reduce mechanical and hydraulic stress.

Typical applications include:

• Water supply pumping stations.
• Industrial circulation pumps.
• Process-water systems.
• Large centrifugal pumps.
• Wastewater treatment equipment.

2. Industrial Fans and Ventilation Systems

Large fans are used in manufacturing plants, power facilities, ventilation systems, and industrial processing equipment.

The ATS48C66Y can manage motor startup and stopping to reduce sudden mechanical torque changes. This can be useful for large fan assemblies with substantial rotational inertia.

3. Compressors

Industrial compressors may require high starting torque and controlled acceleration, depending on the compressor type and operating conditions.

The soft starter can help manage the motor’s startup process and reduce electrical and mechanical stress. Compressor-specific unloading arrangements and starting requirements must be considered during system design.

4. Conveyor Systems

Large conveyor installations may transport bulk materials across mining, manufacturing, and processing facilities.

Controlled starting can help reduce sudden tension changes in conveyor belts and mechanical transmission components. The ATS48C66Y may be used in suitable motor-driven conveyor applications where its current and duty ratings match the equipment requirements.

5. Mining and Material Processing

Mining and material-processing plants use high-power motors to operate pumps, fans, conveyors, crushers, and other heavy machinery.

A suitable soft starter can help manage motor starting conditions and reduce the mechanical impact of abrupt acceleration.

The selected starter must be evaluated against the load’s starting torque, inertia, operating frequency, and environmental conditions.

6. Water and Wastewater Infrastructure

Large motors in water and wastewater facilities often operate pumps and ventilation equipment. Controlled starting and stopping can help improve the mechanical operating conditions of these systems.

The ATS48C66Y’s high-current capability makes it relevant to appropriately rated installations, subject to the required electrical and environmental design.

Installation and System Integration

The ATS48C66Y is a high-current industrial device. Installation should follow Schneider Electric’s technical documentation and applicable electrical standards.

1. Verify Supply Voltage and Motor Ratings

Confirm that the incoming supply is within the device’s 208–690 V AC operating range.

Check the motor nameplate for:

• Rated voltage.
• Rated current.
• Rated power.
• Frequency.
• Starting characteristics.
• Service duty.

The soft starter must be selected according to the actual motor current and application conditions, not simply the motor’s nominal kilowatt rating.

2. Select Suitable Upstream Protection

The installation requires appropriately rated upstream protection and isolation equipment.

Circuit breakers, fuses, contactors, and conductors must be selected according to the manufacturer’s coordination requirements and applicable electrical codes.

Protection should account for the available short-circuit current, motor characteristics, installation conditions, and the starter’s specified ratings.

3. Provide a Suitable Enclosure

The ATS48C66Y has an IP00 enclosure rating. It does not provide complete protection against accidental contact, dust, or water.

The unit must be installed inside a suitable electrical cabinet or protected electrical installation. The cabinet should provide sufficient space for power connections, control wiring, maintenance access, and heat dissipation.

4. Confirm Mounting Dimensions and Weight

The supplied dimensions are 670 × 400 × 300 mm, and the weight is 51.4 kg.

Allow sufficient space for mounting, ventilation, cable routing, and maintenance. The panel structure must support the device’s weight and withstand the mechanical conditions of the installation.

5. Connect Control Wiring

The control circuit operates from a 110–230 V AC supply. Control wiring should be separated from high-current power wiring where appropriate.

Configure the discrete inputs and outputs according to the control strategy. Verify the assignments for run, stop, fault indication, starting-complete status, and other required signals.

6. Configure Motor Parameters

Set the motor current and other relevant parameters according to the motor nameplate and application.

Incorrect current settings can affect motor protection and starting performance. The factory current setting should not automatically be assumed to match every connected motor.

7. Commissioning and Functional Testing

Before returning the system to operation:

1. Inspect the power and control wiring.
2. Verify grounding and protective-device coordination.
3. Confirm the motor nameplate settings.
4. Test the start and stop commands.
5. Observe motor acceleration and stopping behavior.
6. Check fault and status outputs.
7. Confirm PLC and communication functions where applicable.
8. Record the final configuration for maintenance purposes.

High-current motor installations should be commissioned by qualified personnel using the appropriate safety procedures.

Compatible System Components

The ATS48C66Y normally operates as part of 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 ATS48C66Y.

Alternative Models and Replacement Considerations

The ATS48C66Y has been discontinued. Schneider Electric identifies the ATS480C66Y from the Altivar ATS480 series as its recommended replacement.

The ATS480C66Y should not be treated as a completely interchangeable component without engineering review. Before replacement, compare:

• Rated supply voltage.
• Normal-duty and heavy-duty current ratings.
• Motor power at the actual supply voltage.
• Starting and stopping control functions.
• Control supply voltage.
• Discrete input and output arrangements.
• Communication capabilities.
• Bypass and protection requirements.
• Mounting dimensions and cabinet ventilation.
• Parameter configuration and PLC integration.

A replacement project may require wiring changes, control-system modifications, updated parameter settings, and recommissioning.

Key Advantages

Controlled Motor Starting

The Altistart 48 uses torque-control technology to manage motor acceleration and reduce abrupt starting conditions.

High-Current Capability

With a published nominal soft-start current rating of 660 A, the ATS48C66Y is designed for large industrial motor applications.

Wide Supply Voltage Range

Its 208–690 V AC supply range supports a variety of industrial electrical systems.

Motor and Starter Protection

Built-in protection functions help monitor operating conditions and identify faults associated with motor and starter operation.

Configurable Control Signals

Discrete inputs, logic outputs, and relay outputs support integration with PLCs and other control equipment.

Communication Capability

The RJ45 Modbus interface provides a communication path for compatible industrial control systems.

Industrial Application Flexibility

The ATS48C66Y can be used in suitable pumping, fan, compressor, conveyor, and material-processing applications when correctly sized and configured.

Technical FAQs

1. What is the Schneider Electric ATS48C66Y?

The ATS48C66Y is an Altistart 48 soft starter designed for controlled starting and stopping of three-phase asynchronous motors.

2. What is the rated current of the ATS48C66Y?

Its published factory current setting is 590 A, while its nominal soft-start current rating is 660 A for the specified in-line connection. These figures refer to different rating parameters and should not be treated as identical.

3. What voltage does the ATS48C66Y support?

It supports a supply voltage range of 208–690 V AC and operates with a 50/60 Hz supply.

4. What is the control supply voltage?

The control circuit supply range is 110–230 V AC at 50/60 Hz.

5. What is the maximum motor power?

The maximum published rating reaches 630 kW at 660 V or 690 V for certain standard-duty applications. The applicable motor power depends on voltage and duty classification.

6. Does the ATS48C66Y support Modbus communication?

Yes. The Altistart 48 provides a Modbus communication interface through its RJ45 connector. Additional network integration may require suitable communication hardware.

7. What protection functions are available?

The device includes protection functions related to motor thermal conditions, starter thermal conditions, and phase failure. The overall installation still requires appropriate upstream electrical protection.

8. What is the enclosure protection rating?

The ATS48C66Y has an IP00 rating. It must be installed in a suitable protected electrical cabinet or installation.

9. Is the ATS48C66Y still available from Schneider Electric?

Schneider Electric discontinued the model on August 7, 2023. Existing units may still be available through industrial spare-parts suppliers, but availability and condition should be confirmed.

10. What is the recommended replacement?

Schneider Electric identifies the ATS480C66Y as the recommended replacement. However, the replacement should be evaluated against the original system’s electrical, mechanical, and control requirements.

11. What is the weight of the ATS48C66Y?

The published weight is approximately 51.4 kg. The supplied listing dimensions are 670 × 400 × 300 mm.

Procurement and Maintenance Recommendations

When purchasing the ATS48C66Y, verify the complete model number and inspect the product identification label. Since the model has been discontinued, procurement may involve new-old-stock, refurbished, or used equipment.

For surplus or refurbished units, request clear photographs of the front panel, terminals, identification label, and internal condition where inspection is permitted. Confirm whether the unit has been functionally tested and ask about warranty and return conditions.

For high-current applications, verify the exact electrical rating and operating condition before installation. A unit with the correct model number may still require inspection for storage damage, contamination, loose terminals, or deterioration of internal components.

Maintenance should include checking terminal tightness, ventilation paths, cabinet temperature, wiring condition, and the operation of control signals. Follow the manufacturer’s maintenance instructions and the facility’s electrical safety procedures.

When planning a replacement with ATS480C66Y, review the entire motor-control arrangement rather than comparing only the current rating. Confirm the control supply, communication interface, motor duty, bypass configuration, protection coordination, and cabinet layout before commissioning.

Conclusion

The Schneider Electric ATS48C66Y Altistart 48 is a high-current soft starter designed for three-phase asynchronous motors in demanding industrial applications. It supports a 208–690 V AC supply range, has a published factory current setting of 590 A, and provides a nominal soft-start current rating of 660 A for the specified in-line connection.

With torque-controlled starting and stopping, motor and starter protection, configurable control signals, and Modbus communication capability, the ATS48C66Y can support large pumping, fan, compressor, conveyor, and material-processing systems.

As the model has been discontinued, accurate identification and technical compatibility checks are essential when sourcing spare parts or planning equipment replacement. Schneider Electric recommends the ATS480C66Y as its successor, subject to a complete application and installation review.