Product Overview

The Schneider Electric ATS490C48Y Altivar Soft Starter is an industrial motor-starting device designed to control the acceleration and deceleration of three-phase asynchronous motors. Belonging to the Altivar Soft Starter ATS490 family, it provides controlled motor starting and stopping for industrial machinery, process equipment, and infrastructure applications.

When a large AC motor starts directly across the line, it can draw a high inrush current and produce substantial mechanical stress. This may affect the electrical supply and place additional strain on couplings, belts, gearboxes, pumps, and other connected equipment.

A soft starter helps manage this process by progressively controlling the voltage applied to the motor during starting. The ATS490C48Y is designed to provide controlled acceleration and stopping, helping industrial systems achieve smoother motor operation and more predictable starting performance.

The ATS490C48Y has a rated operational current of 480 A and supports operating voltages from 208 to 690 V AC. Its published normal-duty motor ratings vary according to supply voltage and connection method. For example, the rated motor power for an in-line connection is 250 kW at 400 V, while the inside-delta rating at the same voltage is 355 kW. Actual motor selection must follow the manufacturer’s duty tables and installation requirements.

The device includes an internal bypass, torque-control functionality, integrated motor overload protection, and monitoring features. Its control supply supports 110–230 V AC, with a 24 V DC control supply option also specified in product data. The exact control wiring should be checked against the applicable documentation.

With a rated current of 480 A, the ATS490C48Y is intended for substantial industrial motor applications rather than small machinery. It can be used in systems where controlled starting, stopping, and motor protection are important to equipment operation.

Technical Specifications

Motor power ratings depend on supply voltage, connection method, duty classification, and operating conditions. Always consult the manufacturer’s selection tables before choosing a motor and soft starter combination.

Function and Working Principle

The ATS490C48Y controls the starting and stopping process of an asynchronous motor. Rather than applying full supply voltage immediately, the soft starter regulates the motor’s electrical conditions during acceleration and deceleration.

1. Controlled Motor Starting

When a motor starts directly across the line, the initial current can be several times higher than its rated operating current. The resulting electrical and mechanical stresses may affect the motor, power distribution system, and driven equipment.

The ATS490C48Y gradually increases the voltage applied to the motor according to the configured starting parameters. This helps manage the starting current and provides a smoother acceleration process.

The actual current reduction depends on the motor, load torque, starting time, and selected settings. A soft starter does not eliminate starting current; it controls the starting process within the capabilities of the motor and device.

2. Controlled Motor Stopping

The soft starter can also manage motor deceleration. This is particularly useful in applications where an abrupt stop could cause pressure changes, product movement, or mechanical shock.

For example, in a pumping system, controlled stopping can help reduce sudden changes in fluid flow. In material-handling equipment, it can help reduce abrupt mechanical movement.

The stopping method must be selected according to the driven load. A soft starter is not a substitute for a dedicated variable-frequency drive when continuous speed regulation is required.

3. Torque Control

The ATS490C48Y supports torque-control functionality. This allows the starting or stopping process to be managed with attention to motor torque behavior rather than relying only on a simple voltage ramp.

Torque control can be useful in applications where the load requires a more controlled acceleration profile. The appropriate settings depend on motor characteristics, load inertia, and the required starting performance.

4. Internal Bypass Operation

The ATS490C48Y includes an internal bypass. Once the motor has completed its starting process and reaches the intended operating condition, the bypass function reduces the power losses associated with continuous operation through the starting power electronics.

This can help improve operating efficiency and reduce heat generated by the power section during normal running.

The bypass function is integrated into the soft starter, but correct installation and operating conditions remain essential.

5. Motor Overload Protection

The ATS490C48Y provides integrated motor overload protection. This function helps protect the motor against prolonged excessive current according to the configured protection settings.

The device also provides monitoring and diagnostic information to support maintenance and troubleshooting. Protection settings must be coordinated with motor nameplate data and the application’s operating requirements.

Role in Industrial Control Systems

The ATS490C48Y is commonly installed within a motor-control panel as part of a larger industrial automation system. It manages motor starting and stopping while other control equipment coordinates the overall production process.

PLC Integration

A programmable logic controller can issue start and stop commands and coordinate the soft starter with sensors, valves, pumps, conveyors, and other equipment.

The ATS490 series supports industrial communication options, including Modbus TCP and EtherNet/IP, as well as Modbus serial communication. The actual communication arrangement should be verified for the installed device and network configuration.

Through the control system, operators and automation logic can coordinate motor operation with process conditions and equipment interlocks.

HMI and Operator Monitoring

A human-machine interface can provide operators with information about motor status, operating conditions, alarms, and fault events.

The ATS490C48Y supports display-based operation and monitoring. In a larger system, the HMI may communicate with the PLC or the soft starter through an appropriate communication interface.

This allows operators to monitor equipment without accessing the electrical cabinet for routine status checks.

Electrical Distribution Coordination

The soft starter is installed between the incoming power supply and the motor. It must be coordinated with upstream circuit breakers, fuses, disconnect devices, and the motor’s electrical protection arrangement.

For a 480 A soft starter, conductor sizing, short-circuit protection, cabinet design, and heat management require careful engineering.

Process Equipment Coordination

The ATS490C48Y can be used in applications where motor starting and stopping need to be coordinated with the production sequence.

For example, a PLC may start a pump after a valve reaches the required position or stop a conveyor when a downstream machine reports a fault. The soft starter manages the motor’s starting and stopping process while the control system manages the wider equipment sequence.

Industrial Applications

The ATS490C48Y is designed for high-current industrial motor applications. Its 480 A rating makes it suitable for appropriately selected motors in process industries, infrastructure facilities, and heavy industrial equipment.

1. Industrial Pumping Systems

Large pumps are frequently used in water treatment, chemical processing, manufacturing, and industrial utilities.

Controlled starting can help reduce the electrical and mechanical stresses associated with starting large pump motors. Controlled stopping can also help manage changes in fluid flow.

The final selection must consider pump torque, fluid characteristics, motor ratings, and the required starting time.

2. Industrial Fans and Blowers

Large ventilation systems and industrial blowers may use high-power asynchronous motors. A soft starter can help reduce abrupt mechanical movement during motor acceleration.

It can also support controlled stopping when the process requires a gradual shutdown.

3. Conveyor Systems

Heavy conveyor systems often involve substantial mechanical inertia and significant starting loads. Controlled motor starting can help reduce mechanical shock to belts, gearboxes, couplings, and connected structures.

The ATS490C48Y may be suitable for conveyor motors whose current and starting requirements fall within the device’s ratings.

4. Compressors

Industrial compressors may use large asynchronous motors to drive air or gas compression equipment. Controlled starting can help manage the electrical demand and mechanical stress associated with motor acceleration.

The compressor’s starting torque requirements, unloading arrangements, and operating sequence must be considered when configuring the soft starter.

5. Water and Wastewater Infrastructure

Pumping stations, treatment facilities, and water distribution systems often operate large motors under changing process conditions.

The ATS490C48Y can be incorporated into motor-control panels where controlled starting, stopping, and protection are required. PLC and HMI integration can support centralized monitoring and process coordination.

6. Industrial Process Machinery

Large mixers, processing equipment, and other industrial machines may require controlled motor acceleration to avoid sudden mechanical loading.

The soft starter can support these applications when its current rating, motor duty, and starting characteristics are properly matched to the equipment.

Installation and System Integration

Correct installation is essential for safe operation and reliable performance. The ATS490C48Y is a high-current device, so electrical design and installation should be performed by qualified personnel.

1. Verify the Electrical Supply

Confirm that the supply voltage is within the device’s specified 208–690 V AC operating range. Check the supply frequency, phase configuration, motor voltage, and motor nameplate current.

The rated current of 480 A should not be treated as a universal motor-power rating. Motor selection depends on supply voltage, duty classification, connection method, ambient temperature, and application requirements.

2. Confirm Motor Compatibility

Before connecting the motor, verify:

• Motor rated voltage and current.
• Normal-duty or heavy-duty operating requirements.
• Starting torque requirements.
• Motor connection method.
• Expected starting frequency.
• Acceleration and stopping requirements.
• Ambient temperature and cooling conditions.

For in-line and inside-delta installations, follow the manufacturer’s wiring diagrams and motor selection tables. These connection methods have different current and motor-power ratings.

3. Panel Mounting and Dimensions

The supplied dimensions are 455 × 304 × 300 mm, and the product weight is 28 kg.

Allow sufficient space for mounting, electrical connections, heat dissipation, and maintenance access. The panel must be designed to accommodate the device’s heat losses and the ventilation requirements of the complete motor-control assembly.

The specified IP00 protection rating means the soft starter requires suitable enclosure protection. It should not be installed in an environment where personnel or equipment can be exposed to unprotected live components.

4. Power Wiring and Protection

The incoming supply, motor connections, protective devices, and grounding arrangement must comply with the manufacturer’s instructions and applicable electrical codes.

Because the ATS490C48Y is rated at 480 A, conductor sizing and connection methods are particularly important. Use correctly rated terminals, cables, busbars, and protective devices.

Ensure that upstream short-circuit protection is coordinated with the soft starter’s ratings and the available fault current.

5. Control Wiring

Connect the control supply and command circuits according to the correct wiring diagram. The control supply configuration should be checked before energizing the device.

Where PLC integration is required, verify the communication interface, network settings, control commands, and feedback signals. Test all start, stop, fault, and interlock functions before putting the equipment into service.

6. Parameter Configuration

Configure the motor’s rated current and the appropriate starting and stopping parameters. Set the overload protection and other application-specific functions according to the motor and driven load.

Incorrect settings can cause nuisance trips, excessive starting time, or inadequate motor protection.

7. Commissioning and Testing

Before commissioning, inspect all power and control connections, verify grounding, and confirm the motor’s mechanical condition.

Test the starting sequence, stopping behavior, bypass operation, overload protection, communication, and fault response. Record the final configuration for future maintenance and replacement work.

Compatible System Components

The ATS490C48Y is generally used with industrial electrical and automation components that support its high-current motor-control application.

The components listed above are examples of equipment used in a complete motor-control installation. They are not necessarily included with the ATS490C48Y.

Alternative Models and Replacement Considerations

The ATS490 family contains models with different current ratings and motor-power capabilities. When selecting an alternative, the replacement must be evaluated against the motor’s actual electrical and mechanical requirements.

When considering a replacement, compare:

• Rated operational current.
• Supply voltage range.
• Motor power at the actual operating voltage.
• Normal-duty and heavy-duty requirements.
• In-line or inside-delta connection.
• Control supply voltage.
• Internal bypass arrangement.
• Torque-control requirements.
• Communication interfaces.
• Motor overload protection settings.
• Mounting dimensions and heat dissipation.
• Upstream short-circuit protection requirements.

A soft starter with a higher current rating is not automatically a direct replacement. The complete motor-control design must be checked before changing models.

Key Advantages

Controlled Motor Starting

The ATS490C48Y manages motor acceleration to help reduce the electrical and mechanical stresses associated with direct-on-line starting.

Controlled Stopping

Configurable stopping behavior can help reduce abrupt mechanical movement and support smoother process shutdowns.

High Current Capacity

Its 480 A rated operational current supports appropriately selected large industrial motors.

Integrated Bypass

The internal bypass reduces the need for a separate external bypass arrangement and helps limit operating losses after the motor has started.

Torque Control

Torque-control functionality supports applications where motor acceleration and deceleration need more precise management.

Integrated Motor Overload Protection

The built-in overload protection helps monitor motor operating conditions and supports equipment protection when correctly configured.

Industrial Communication

Modbus TCP, EtherNet/IP, and Modbus serial communication capabilities can support integration into suitable automation architectures, subject to the installed configuration.

Process Monitoring

Monitoring and diagnostic functions help maintenance personnel evaluate operating conditions and identify potential faults.

Technical FAQs

1. What is the Schneider Electric ATS490C48Y?

The ATS490C48Y is an Altivar Soft Starter designed to control the starting and stopping of three-phase asynchronous motors. It has a rated operational current of 480 A.

2. What voltage range does the ATS490C48Y support?

Its rated operating voltage range is 208–690 V AC. The actual motor rating depends on the supply voltage and connection method.

3. What is the rated current of this soft starter?

The rated operational current is 480 A under the specified operating conditions.

4. What is the motor power rating at 400 V?

For normal-duty in-line operation, the published motor power rating is 250 kW at 400 V. For inside-delta operation, the published rating is 355 kW. The correct selection must follow the manufacturer’s motor and connection tables.

5. Does the ATS490C48Y have an internal bypass?

Yes. The model includes an internal bypass that operates after the starting process, helping reduce power losses during normal running.

6. Does this model support torque control?

Yes. Torque-control functionality is included and can be configured according to the motor and application requirements.

7. What control supply voltage does it use?

Product data specifies a 110–230 V AC control supply and a 24 V DC option. Confirm the exact control supply arrangement and wiring before installation.

8. Can the ATS490C48Y communicate with a PLC?

Yes. The ATS490 platform supports industrial communication options such as Modbus TCP, EtherNet/IP, and Modbus serial. Confirm the required interface and configuration for the actual installation.

9. What is the weight of the ATS490C48Y?

The manufacturer’s catalog lists a weight of approximately 28 kg for this model. The supplied product listing weight is also 28 kg.

10. Is the ATS490C48Y a variable frequency drive?

No. It is a soft starter. It controls motor acceleration and stopping but does not provide the same continuous motor-speed regulation as a variable frequency drive.

Procurement and Maintenance Recommendations

When purchasing the Schneider Electric ATS490C48Y, verify the complete model number and confirm that the device’s current and voltage ratings match the motor-control application.

For replacement projects, check whether the existing installation uses an in-line or inside-delta connection. This distinction affects the motor-power rating and wiring arrangement. Also verify the control supply, communication requirements, bypass configuration, and protection settings.

Before ordering, confirm the product’s physical condition, nameplate information, terminal condition, and included accessories. For used or refurbished equipment, request clear product photographs and available functional test information. Confirm warranty and return conditions before purchase.

For maintenance, inspect the power connections, control wiring, grounding, ventilation, and cabinet condition according to the manufacturer’s maintenance recommendations. Review fault records and operating parameters when troubleshooting repeated trips or abnormal motor behavior.

The 480 A rating makes electrical installation quality particularly important. Power conductors, busbars, protective devices, and enclosure thermal design must all be suitable for the intended application.

Conclusion

The Schneider Electric ATS490C48Y Altivar Soft Starter is a high-current motor-starting device designed for industrial asynchronous motors. With a rated operational current of 480 A and an operating voltage range of 208–690 V AC, it supports controlled starting and stopping in appropriately designed motor-control systems.

Its internal bypass, torque-control capability, integrated motor overload protection, and industrial communication options make it suitable for demanding applications in pumping, ventilation, material handling, and industrial processing.

For installation or replacement, engineers should verify the motor’s current and power requirements, connection method, control supply, protection coordination, and communication configuration. Correct selection and commissioning are essential for reliable operation.