BOSTON GEAR CONTROLLERS ACE 20 Series 1/8 through 10 HP Adjustable Frequency AC Motor Controllers
ACE 20 Series Offering full-featured control in high torque, low speed applications from 1/8 to 10 HP, ACE 20 motor controllers are versatile performers for conveyors, packaging equipment, machine tool, extruders, mixers, fans, pumps, wastewater treatment facilities and other uses where cool, quiet motor operation is desired. All models can be used in adjustable frequency sensorless torque mode or conventional volts/hertz mode. When programmed in sensorless torque (dynamic vector) mode, the controller achieves full torque ratings down to 1 Hz without need for external feedback devices. Other operating advantages include internal PID loop control enabling automatic output adjustment based on changes in process flow, pressure or fluid levels, making these compact units ideal for uses in petrochemical operations as well as HVAC systems. Extensive programming capabilities plus compatibility with Modbus RTU communication protocol allow ACE 20 controllers to handle a wide range of automated system processes. ACE Controller Family Boston Gear introduces our newest family of adjustable frequency AC motor controllers _ The ACE Series. Four different series of controllers cover a horsepower range of fractional to 800 HP for both constant and variable torque applications. These controllers utilize the latest in IGBT technology for cooler and quieter motor operation and operate using either V/Hz, open loop sensorless torque (dynamic vector) or closed loop vector control. Please contact your local representative for application assistance and information on the other ACE series controllers. Features 1/8-10 Horsepower Ratings 230/460 VAC Three Phase Input (Three Phase Output).75-15 khz Carrier Frequency _ selectable, for cool, quiet motor operation NEMA 1 Enclosed _ for use as stand alone unit or in customer s enclosure Two Control Methods Volts/Hertz Open Loop Sensorless Torque _ for low speed operation UL /cul /CE Mark _ world wide acceptance Isolated Speed Reference _ for operator safety Programmable Digital Inputs/Outputs _ for multiple drive and system operation Analog Input/Output _ for use with meters and follower applications Fault History _ Last 4 faults for diagnostics Built in Dynamic Brake Transistor Motor Tuning _ for sensorless torque operation parameters LED Keypad and Status Indicators _ monitors operating parameters RS 485 RTU Serial Communications _ low cost system integration Built-in PID Control _ allows control to correct for fluctuations in processes Ground Fault Protection _ protects the controller against motor short to ground Energy Saving Mode _ used to reduce electric usage Available Options Electronic Braking Resistor _ for frequent stopping Monitoring Hardware and Software _ Windows based program for setup and monitoring Communication Cards _ ACE20 series can be used with popular communication busses: Profibus-DP Interbus-S DeviceNet ModbusPlus
ACE 20 Specifications Output Ratings Input Ratings Braking Output Frequency Control Operation Keypad Environment Category 230 VAC Voltage 460 VAC Drive horsepower 1/8 to 10 HP 1/2 to 10 HP Rated voltage (three phase) 200V / 50 Hz 380, 400, 415 V / 50 Hz 200, 220, 230V / 60 Hz (with AVR function) 380, 400, 440 V / 60 Hz (with AVR function) Overload current rating 150% of rated output current for 1 minute 200% of rated output current for 0.5 second Rated frequency 50, 60 Hz Voltage 200 to 230 VAC (three phase) 380 to 480 VAC (three phase) Voltage fluctuation +10 to -15% Voltage unbalance 2% or less Frequency 50 or 60 Hz Frequency fluctuation +5 to -5% When the input voltage drops below 165VAC, When the input voltage drops below 300VAC, Resistance to Instantaneous voltage drop operation continues at 165VAC or higher voltage. operation continues at 300VAC or higher voltage. operation continues for 15 ms operation continues for 15 ms 100% (1/8-1/4 HP) 70% (1/2-2 HP) Braking. torque (Internal braking) 70% (1/2-2 HP) 40% (3-5 HP) 40% (3-5 HP) 20% (7-1/2-10 HP) 20% (7-1/2-10 HP) Braking torque (external braking resistor) 150% Starting frequency 0.2 to 60.0 Hz DC braking Braking current 0 to 100% Braking time 0.0 to 30.0 seconds Control method Sinusoidal wave PWM control (with V/Hz-control, sensorless torque control) Maximum frequency 50 to 400 Hz Adjustment Base frequency 25 to 400 Hz Starting frequency 0.1 to 60.0 Hz, holding time: 0.0 to 10.0 seconds Carrier frequency 0.75 to 15 khz (the carrier frequency may automatically drop to 0.75 khz to protect the drive) Stability Analog ± 0.2% (25, ±10 C) Digital 0.01% (-10 to +50 C) Resolution Analog 1/3000 of maximum output frequency Digital 0.01 Hz (0.00 to 99.9 Hz), 0.1 Hz (100.0 to 400.0 Hz) Link 1/20000 of maximum frequency or 0.01 Hz (Fixed) Voltage /frequency characteristics Adjustable at base and maximum frequency, with AVR control 80 to 240 V 160 to 480 V Torque boost Automatic Automatic torque boost can be selected with a function code setting Manual 31 different torque boost characteristics can be selected Starting torque 200% or above (with dynamic torque vector turned on, during 0.5 Hz operation) Range 0.01 to 3600 seconds Acceleration / Number 2 acceleration and 2 deceleration settings Deceleration time Types Linear, s-curve (weak, strong), non-linear Bias frequency -400 to +400 Hz Gain (frequency setting) 0 to 200% Jump frequency Number 3 Band width 0 to 30 Hz Slip compensation control 0.00 to +15.00 Hz Droop control 9.9 to 0.0 Hz Additional functions Frequency upper and lower limits, pick-up operation, restart after momentary power failure, automatic energy saving operation, torque limiting (2), torque control, PID control, cooling fan ON/OFF control Keypad Starting and stopping with RUN and STOP keys Operation method Terminal input Forward (reverse) operation, stop command (3-wire operation possible), coast-to-stop command, external alarm, error reset, etc Link operation RS485 modbus RTU (standard) Keypad ^ and keys External potentiometer 5 k Ohm, 1/2 W 0 to ± 5 VDC, 0 to ± 10 VDC, 4 to 20 ma DC, 0 to +10 VDC / 0 to 100% speed can be switched Frequency setting Analog input externally to +10 to 0 / 0 to 100% speed, 4 to 20 ma DC / 0 to 100% speed can be switched externally to 20 to 4 ma / 0 to 100% speed Isolated Yes Digital inputs External signals to control the UP or DOWN command Multistep frequency Up to 16 different frequencies can be selected by digital input signals Program operation Pattern operation by parameter selection Reference power supply voltage 10 VDC Operation Transistor output 2 signals; running, frequency arrival, overload early warning, etc. Status Relay output 1 signal; alarm signal Signal Analog output 1 signal; output frequency, output current, output torque, input power, output voltage, Pulse output Load factor, PID feedback value, etc. Digital display LED Digits 4 digits Settings Output frequency, output current, error messages, various function codes for programming Lamp display Power on, run, panel control, operating mode Protection functions Over current, short-circuit, ground fault, over voltage, under voltage, overload, overheating, motor overload, external alarm, input open-phase, output open-phase (when tuning), braking resistor protection, CPU and memory error, keypad communications error Fault codes stored in memory Last 4 Ambient temperature Altitude Relative humidity Conditions Vibration Storage Ambient temperature Humidity Enclosures Optional ^ -10 to +40 C (+14 to 104 F) 3300 Feet (1000 meters) without derating 5 to 95% (non condensing) Free from corrosive gas, dust and direct sunlight 3mm peak from 2 to 9 Hz, 9.8 m/s2 from 9 to 20 Hz, 2 m/s2 from 20 to 55 Hz, 1 m/s2 from 55 to 200 Hz -25 to 65 C (-13 to 149 F) 5 to 95% (non condensing) Standard NEMA1 IP20 chassis
BOSTON GEAR CONTROLLERS Dimensions W D WI D1 HI H Enclosure Voltage - HP H W D H1 W1 D1 230V - 1/8 & 1/4 6.06 2.76 3.98 4.72 2.24 0.59 230V - 1/2 HP 6.06 2.76 4.65 4.72 2.24 1.26 230V - 1 HP 6.06 2.76 5.67 4.72 2.24 2.28 230V - 2 & 3 HP 6.06 4.17 5.91 4.65 3.87 2.52 230V - 5 HP 6.06 6.69 6.22 4.65 6.21 2.83 230V - 7 1/2 & 10 HP 8.66 7.00 6.22 8.07 6.46 460V - 1/2 HP 6.06 4.17 4.96 4.65 3.87 1.57 460V - 1 HP 6.06 4.17 5.91 4.65 3.87 2.52 460V - 2 & 3 HP 6.06 4.17 6.69 4.65 3.87 2.52 460V - 5 HP 6.06 6.69 6.22 4.65 6.21 2.83 460V - 7 1/2 & 10 HP 8.66 7.00 6.22 8.07 6.46 Wiring Diagram Operator Panel *External braking resistor (DB) G P (+) Analog input P Power supply 3-phase 380 to 480V 50/60Hz or 200 to 230V 50/60Hz DB DB 2 1 * MCCB or ELCB Voltage input (0 to +10V DC) Current input (4 to 20mA DC) (CM) (THR) 3 2 1 L1/R L2/S L3/T G 13 12 11 C1 U V W G P1 P(+) DB N(-) 30 30C 30B P1 P(+) (* 1) *Motor M Alarm output (for any fault) E Where DC REACTOR * is used 4 Digit LED Displays various function codes and data codes for programming along with the output frequency, current or other data during operation along with error messages Status Indicators display when in Run mode and when operating from the keypad Unit Indicators 3 LED s display units of measurement for output display RUN Key starts operation STOP Key stops operation Digital input Forward command Reverse command Analog meter * Analog monitor To terminal 11 PLC FWD REV X1 X2 X3 X4 X5 CM FM 30A P24 Y2 Y1 CME Analog/ pulse changover switch Transistor output FM Pulse counter To terminal 11 (* Digital freq. meter) Program (PRG)/RESET Key switches between operation and programming modes, also resets control after fault (FUNC)/DATA Key switches between frequency, output current and other output displays. In the programming mode used to retrieve and write function and data codes UP/DOWN Keys increases or decreases the frequency during operation, changes function codes and data during programming * Customer supplied
Visit www.bostongear.com Parameter List Fundamental s F00 Data Protection F01 Frequency 1 F02 Operation Method F03 Maximum Output Frequency 1 F04 Base Frequency 1 F05 Rated Voltage 1 F06 Maximum Voltage 1 F07 Acceleration Time 1 F08 Deceleration Time 1 F09 Torque Boost 1 F10 Electronic Thermal Overload Relay 1 (Select) F11 Electronic Thermal Overload Relay 1 (Level) F12 Electronic Thermal Overload Relay 1 (Thermal Time Constant) F13 Electronic Thermal Overload Relay (For External Braking Resistor) F14 Restart Mode After Momentary Power Failure F15 Frequency Limiter (High) F16 Frequency Limiter (Low) F17 Gain (Frequency Setting) F18 Bias Frequency F20 DC Brake (Starting Frequency) F21 DC Brake (Braking Level) F22 DC Brake (Braking Time) F23 Starting Frequency F24 Starting Frequency (Holding Time) F25 Stop Frequency F26 Motor Sound (Carrier Frequency) F27 Motor Sound (Sound Tone) F29 FMA & FMP Terminals (Select) F30 FMA (Voltage Adjust) F31 FMA () F33 FMP (Pulse Rate) F34 FMP (Voltage Adjust) F35 FMP () F36 Alarm Output F40 Torque Limiter 1 (Driving) F41 Torque Limiter 1 (Braking) F42 Torque Vector Control 1 Extension Terminal s/digital Input/Output s E01 05 X1 5 Terminal E10 Acceleration Time 2 E11 Deceleration Time 2 E16 Torque Limiter 2 (Driving) E17 Torque Limiter 2 (Braking) E20 21 Y1-2 Terminal E29 Frequency Level Detection Delay E30 FAR Signal (Hysteresis) E31 FDT Signal (Level) E32 FDT Signal (Hysteresis) E33 OL Signal (Mode Select) E34 OL Signal (Level) E35 OL Signal (Timer) E40 Display Coefficient A E41 Display Coefficient B E42 LED Display Filter Control s of Frequency C01 3 Jump Frequency 1-3 C04 Jump Frequency Hysteresis C05 19 Multistep Frequency 1-15 C21 Timer Operation C22 Timer Duration C30 Frequency Command 2 C31 Analog Setting Signal Offset Adjustment (Terminal 12) C32 Analog Setting Signal Offset Adjustment (Terminal C1) C33 Analog Signal Filter Motor Parameters P01 P02 Number of Motor 1 Poles Motor 1 (Capacity) P03 Motor 1 (Rated Current) P04 Motor 1 (Tuning) P05 Motor 1 (Online Tuning) P06 Motor 1 (No Load Current) P07 Motor 1 (% R1 Setting) P08 Motor 1 (% X Setting) P09 Motor 1 (Slip Compensation Control 1) P10 Motor 1 (Slip Compensation Response Time 1) High Performance s H01 H02 H03 H04 H05 H06 H07 H09 H10 H11 H12 H13 H14 H20 H21 H22 H23 H24 H25 H26 H27 H28 H30 H31 H32 H33 H34 H35 Monitor - Total Operating Time Monitor - Trip History Data Initializing (Data Reset) Auto Reset (Times) Auto Reset (Reset Interval) Fan Stop Operation ACC/DEC Pattern (Mode Select) Start Mode (Rotating Motor Pickup) Energy Saving Operation Decel Mode Instantaneous Overcurrent Limiting Auto Restart (Restart Time) Auto Restart (Frequency Fall Rate) PID Control (Mode Select) PID Control (Feedback Signal) PID Control (P - Gain) PID Control (I - Integral Time) PID Control (D - Differential Time) PID Control (Feedback Filter) PTC Thermistor (Mode Select) PTC Thermistor (Level) Droop Operation Serial Link ( Select) RS485 (Address) RS485 (Mode Select on No Response Error) RS485 (Timer) RS485 (Baud Rate) RS485 (Data Length) H36 H37 H38 H39 H40 H41 H42 H43 H44 H45 H46 RS485 (Parity Check) RS485 (Stop Bits) RS485 (No Response Error Detection Time) RS485 (Response Interval) Monitor - Maximum Temperature of Heat Sink Monitor - Maximum Effective Current Monitor - Main Circuit Capacitor Life Monitor - Cooling Fan Operation Time Monitor - Drive ROM Version Monitor - Keypad Panel ROM Version Monitor - Option ROM Version Alternative Motor Parameters A01 Maximum Output Frequency 2 A02 Base Frequency 2 A03 Rated Voltage 2 A04 Maximum Voltage 2 A05 Torque Boost 2 A06 Electronic Thermal Overload Relay 2 (Select) A07 Electronic Thermal Overload Relay 2 (Level) A08 Electronic Thermal Overload Relay 2 (Thermal Time Constant) A09 Torque Vector Control 2 A10 Number of Motor 2 Poles A11 Motor 2 (Capacity) A12 Motor 2 (Rated Current) A13 Motor 2 (Tuning) A14 Motor 2 (Online Tuning) A15 Motor 2 (No Load Current) A16 Motor 2 (% R1 Setting) A17 Motor 2 (% X Setting) A18 Motor 2 (Slip Compensation Control 2) A19 Motor 2 (Slip Compensation Response Time 2) Order by Catalog Number or Item HP Rated Output Catalog Item Weight Rating Current (A) Number (lbs) 230 VAC, 3 Phase, 50/60 Hz Input, NEMA 1 1/8 0.7 ACE202V3P0001N1 43350 2.4 1/4 1.4 ACE202V3P0002N1 43351 2.4 1/2 2.5 ACE202V3P0005N1 43352 2.8 1 4.0 ACE202V3P0010N1 43353 3.1 2 7.0 ACE202V3P0020N1 43354 5.1 3 10.0 ACE202V3P0030N1 43355 5.1 5 16.5 ACE202V3P0050N1 43356 7.9 7.5 23.5 ACE202V3P0075N1 43357 17.7 10 31.0 ACE202V3P0100N1 43358 17.7 HP Rated Output Catalog Item Weight Rating Current (A) Number (lbs) 460 VAC, 3 Phase, 50/60 Hz Input, NEMA 1 1/2 1.4 ACE204V3P0005N1 43359 4.3 1 2.1 ACE204V3P0010N1 43360 4.7 2 3.7 ACE204V3P0020N1 43361 5.1 3 5.3 ACE204V3P0030N1 43362 5.5 5 8.7 ACE204V3P0050N1 43363 7.5 7 1/2 12.0 ACE204V3P0075N1 43364 17.7 10 16.0 ACE204V3P0100N1 43365 17.7
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