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GEAR
ACE 30 Series
®
ACE® 30 Series
The ACE® 30 Series of controllers from Boston Gear are a full
featured, general purpose, high horsepower, adjustable
frequency AC motor controller that provides the functionality
for variable torque applications such as fans, pumps and
compressors while also having the versatility of a constant
torque controller.
The ACE® 30 has two programmable control methods; the
open loop (sensorless torque) control with auto tuning,
provides superior torque and speed regulation characteristics
required in many applications while the V/Hz control
provides the simplicity wanted in other applications. The
keypad utilizes both digital LED’s and a backlit LCD display Features
which features 5 lines, 13 characters long that can be • Dual Rated
programmed to read in 6 different languages and can be 1/4 – 800 HP Variable Torque (110% Overload,1 Min.)
used to copy functions from one control to another. This 1/4 – 600 HP Constant Torque (150% Overload,1 Min.)
control has many features that are worth noting; RS485 RTU • .75 – 15 kHz Carrier Frequency – selectable, for cool, quiet
serial communications to allow the use of the most popular motor operation
interfaces, disabling reverse operation, built in PID control, • Enclosure Types
dual motor parameters, energy saving operation that NEMA 1, Standard
minimizes the controller and motor loss during light load, NEMA 4, Optional
NEMA 12, Optional
and speed search for starting into a rotating motor. With all
Open Chassis, Optional
these features and reliability the ACE® 30 Series of controls • Two Control Methods
can provide years of trouble free operation. Volt/Hertz PWM Control
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
• Fault History – last 4 faults for diagnostics
• Dynamic Braking
• Motor Auto Tuning – without rotating the motor
• Keypad – monitors operating conditions
Backlit LCD w/Digital LED
Copy Function, Non Volatile
5 Line x 13 Characters
• 50˚ C Ambient Temperature
• RS 485 RTU Serial Communications – low cost system integration
ACE® Controller Family • Built-in PID Control – allows the control to correct for fluctuations
in processes
Boston Gear introduces our newest family of adjustable • Output Fault Protected – protects against motor short to ground
frequency AC motor controllers _ • Dual Motor Parameter Table – presets alternate motor parameters
The ACE® Series. Four different series of controllers • Programmable Pattern Operation – allows preset operation
cover a horsepower range of fractional to 800 HP for Available Options
both constant and variable torque applications. These • Dynamic Braking Resistor Assembly – for frequent stopping
controllers utilize the latest in IGBT technology for cooler • Monitoring Hardware/Software – from a PC or monitoring station
and quieter motor operation and operate using either • Communication Cards
V/Hz, open loop sensorless torque (dynamic vector) or Profibus-DP DeviceNet™ LonWorks
Interbus-S™
ModbusPlus™ Genius™
closed loop vector control. Please contact your local
• Analog and Digital I/O cards
representative for application assistance and information • Chokes and Filters
on the other ACE® series controllers. • Keypad Mounting Kits and Extension Cables
ACE 30 Specifications
®
Category
BOSTONCONTROLLERS
GEAR 230 VAC
1/4 to 150 HP (VT-Variable Torque)
Voltage 460 VAC
1/8 to 800 HP (VT-Variable Torque)
Drive horsepower 1/4 to 125 HP (CT-Constant Torque) 1/8 to 600 HP (CT-Constant Torque)
200V / 50 Hz 380, 400, 415 V / 50 Hz
Output Rated voltage (three phase)
200, 220, 230V / 60 Hz 380, 400, 440 V / 60 Hz
Ratings
110% (VT), 150% (CT) of rated output current for 1 minute
Overload current rating
200% of rated output current for 0.5 second (CT only)
Rated frequency 50, 60 Hz
Voltage 200 to 230 VAC (three phase) 380 to 480 VAC (three phase)
Voltage fluctuation +10 to -15%
Input Voltage unbalance 2% or less
Frequency 50 or 60 Hz
Ratings
Frequency fluctuation +5 to -5%
Operation continues at 165VAC or higher voltage. When the input Operation continues at 310VAC or higher voltage. When the input
Resistance to instantaneous voltage drop voltage drops below 165VAC, operation continues for 15ms (CT only) voltage drops below 310VAC, operation continues for 15ms (CT only)
150% (1/4 - 1 HP) (CT only) 150% (1/2 - 1 HP) (CT only)
100% (2 - 10 HP) (CT only) 100% (2 - 10 HP) (CT only)
Braking torque (Internal braking)
20% (15 - 30 HP) (CT only) 20% (15 - 30 HP) (CT only)
15 to 20% (40 - 125 HP) (CT only) 15 to 20% (40 - 125 HP) (CT only)
Braking 150% (1/4 - 30 HP) (CT only) 150% (1/4 - 30 HP) (CT only)
Braking torque (external braking resistor) 100% (40 - 125 HP) (CT only) 100% (40 - 600 HP) (CT only)
Starting frequency 0.1 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/F control, sensorless torque control)
Maximum frequency 50 to 120 Hz
Base frequency 25 to 120 Hz
Starting frequency 0.1 to 60.0 Hz, holding time: 0.0 to 10.0 seconds
Adjustment Carrier frequency 0.75 to 15 kHz (1/4 - 30 HP (VT)) 0.75 to 15 kHz (1/2 - 30 (VT) HP)
Output 0.75 to 10 kHz (40 - 100 HP (VT)) 0.75 to 10 kHz (40 - 100 (VT) HP)
Frequency 0.75 to 6 kHz (125 - 150 HP (VT)) 0.75 to 6 kHz (125 - 800 (VT) HP)
The minimum carrier frequency changes depending on maximum output frequency
Analog ± 0.2% (25°, ±10°C)
Stability
Digital 0.01% (-10° to +50°C)
Analog 1/3000 of maximum output frequency
Resolution Digital 0.01 Hz (0.00 to 99.9 Hz), 0.1 Hz (100.0 to 120.0 Hz)
Link 1/20000 of maximum frequency or 0.01 Hz (fixed)
Output voltage at base frequency can be adjusted separately
Voltage / frequency characteristics 80 to 240 V 320 to 480 V
Automatic Automatic torque boost can be selected with a function code setting
Torque boost
Manual Different torque boost characteristics can be selected
With sensorless torque control selected (constant torque operation only)
Starting torque 200% (1/4 -30 HP (CT)) 200% (1/2 -30 (CT) HP)
180% (40-125 HP (CT)) 180% (40-600 (CT) HP)
Range 0.01 to 3600 seconds
Acceleration /
Number 4 acceleration and 4 deceleration settings
Deceleration time
Control Types Linear, s-curve (weak, strong), non-linear
Bias frequency 120.0 to + 120.0 Hz
Gain (frequency setting) 0 to 200%
Number 3 bands
Jump frequency
Band width 0 to 30 Hz
Slip compensation control 0.00 to +15.00 Hz
Droop control n/a
Frequency upper and lower limits, pick-up operation, restart after momentary power failure, switching operation
Additional features form line to drive, automatic energy saving operation, regeneration avoiding control, torque limiting (2),
Grounding G G Grounding
Note:
Control Circuit
The control circuit common terminals
[11], (CM) and <CMY> are isolated
[13] +10V DC 0V 30A
Potentiometer (*2) 3
2 30 30B Alarm
[12] relay (*1) Use a drive with rated voltage
Voltage input
0 to +10V DC 1 [11] 30C output matching the power supply
voltage.
It is possible to input voltage signals
Analog (0 to +10V DC or 0 to +5V DC) to terminals
input (*9)
[12]-[11] instead of the potentiometer.
[V2]
SW1 (*2) Use as required.
2nd Voltage input (+)
0 to +/-10V (0V) (*3) Use this peripheral device when
0 to +/-5V Source Sink
[C1] necessary.
Current input (+)
4 to 20mA DC (-) (*4) Remove the jumper wire between
Analog freq. meter
[FMA] P1 and P(+) before connecting a
0 to +10V DC DC REACTOR.
0 to 60Hz
FM (*2)
+24V DC 0V
(P24) (*5) Be sure to use the braking unit
(PLC)
(option) when connecting the
external braking resistor (option)
(FWD)
RS485
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Dimensions NEMA 1
W D
WI
Mounting Dimensions (Inches)
HP Rating Slot
W WI H HI D
VT CT Width
1/4 1/4 4.33 3.78 10.24 9.69 5.12 .24
1/2 1/2 4.33 3.78 10.24 9.69 5.12 .24
1 1 4.33 3.78 10.24 9.69 5.71 .24
2 2 5.91 5.35 10.24 9.69 5.71 .24
3 3 5.91 5.35 10.24 9.69 5.71 .24
5 5 5.91 5.35 10.24 9.69 5.71 .24
7 1/2 5 8.66 7.72 10.24 9.37 7.68 .39
10 7 1/2 8.66 7.72 10.24 9.37 7.68 .39
15 10 8.66 7.72 10.24 9.37 7.68 .39
20 15 9.84 8.90 15.75 14.88 7.68 .39
HI H 25 20 9.84 8.90 15.75 14.88 7.68 .39
30 25 9.84 8.90 15.75 14.88 7.68 .39
Operator Panel
Units Indicator
Indicates selected units or
multiple of the data shown on the
LED monitor
FWD Key
Forward operation
RUN LED
Indicates operation command
from FWD or REV key
Operation Keys
Switching screens, changing REV Key
data, setting frequency, reset Reverse operation
trips, etc.
STOP Key
Stop command
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Parameter List
Fundamental Functions E31 Frequency Detection H13 Auto Restart (Restart Time)
(Operation Level) H14 Auto Restart
F00 Data Protection
E32 Frequency Detection (Frequency Fall Rate)
F01 Frequency Command 1
(Hysteresis Width) H15 Auto Restart
F02 Operation Method
E33 Overload Early Warning (Holding DC Voltage)
F03 Maximum Output Frequency 1
(Operation) H16 Auto Restart (OPR Command Self
F04 Base Frequency 1
E34 Overload Early Warning (Level) Hold Time)
F05 Rated Voltage 1
E35 Overload Early Warning (Timer) H19 Active Drive
F06 Maximum Voltage 1
E36 Frequency Detection 2 H20 PID Control (Mode Select)
F07 Acceleration Time 1
(Operation Level) H21 PID Control (Feedback Signal)
F08 Deceleration Time 1
E37 Overload Early Warning 2 H22 PID Control (P - Gain)
F09 Torque Boost 1
(Operation Level) H23 PID Control (I - Integral Time)
F10 Electronic Thermal Overload
E40 Display Coefficient A H24 PID Control (D - Differential Time)
Relay 1 (Select)
E41 Display Coefficient B H25 PID Control (Feedback Filter)
F11 Electronic Thermal Overload
E42 Display Filter H26 PTC Thermistor (Mode Select)
Relay 1 (Level)
E43 LED Monitor (Display Selection) H27 PTC Thermistor (Level)
F12 Electronic Thermal Overload
E44 LED Monitor (Display at Stopping) H30 Serial Link (Function Select)
Relay 1 (Time Constant)
E45 LCD Monitor (Display Selection) H31 RS485 (Address)
F13 Electronic Thermal Overload
E46 LCD Monitor (Language) H32 RS485 (Mode Select on No
Relay (For External Braking
E47 LCD Monitor (Contrast Response Error)
Resistor)
Adjustment) H33 RS485 (Timer)
F14 Restart Mode After Momentary
H34 RS485 (Baud Rate)
Power Failure Frequency Control Functions H35 RS485 (Data Length)
F15 Frequency Limiter (High)
C01-03 Jump Frequency 1 to 3 H36 RS485 (Parity Check)
F16 Frequency Limiter (Low)
C04 Jump Frequency Hysteresis H37 RS485 (Stop Bits)
F17 Gain (Frequency Setting Signal)
C05 - 19 Multistep Frequency 1 - 15 H38 RS485 (No Response Error
F18 Bias Frequency
C20 Jog Frequency Detection Time)
F20 DC Brake (Starting Frequency)
C21 Pattern Operation H39 RS485 (Response Interval)
F21 DC Brake (Braking Level)
F22 DC Brake (Braking Time) (Operation Selection)
Alternative Motor Parameters
F23 Starting Frequency (Frequency) C22 - 28 Pattern Operation (Stage 1 - 7)
F24 Starting Frequency C30 Frequency Command 2 A01 Maximum Output Frequency 2
(Holding Time) C31 Analog Input Bias Adjustment A02 Base Frequency 2
F25 Stop frequency C32 Analog Input Gain Adjustment A03 Rated Voltage 2
F26 Motor Sound (Carrier Frequency) C33 Analog Setting Signal A04 Maximum Voltage 2
F27 Motor Sound (Sound Tone) A05 Torque Boost 2
Motor Parameters A06 Electronic Thermal Overload
F30 FMA (Voltage Adjust)
F31 FMA (Function) P01 Number of Motor 1 Poles Relay 2 (Select)
F33 FMP (Pulse Rate) P02 Motor 1 (Capacity) A07 Electronic Thermal Overload
F34 FMP (Voltage Adjust) P03 Motor 1 (Rated Current) Relay 2 (Level)
F35 FMP (Function) P04 Motor 1 (Tuning) A08 Electronic Thermal Overload
F36 Alarm Output P05 Motor 1 (Online Tuning) Relay 2 (Time Constant)
F40 Torque Limiter 1 (Driving) P06 Motor 1 (No Load Current) A09 Torque Vector Control 2
F41 Torque Limiter 1 (Braking) P07 Motor 1 (% R1 Setting) A10 Number of Motor 2 Poles
F42 Torque Vector Control 1 P08 Motor 1 (% X Setting) A11 Motor 2 (Capacity)
P09 Motor 1 (Slip Compensation A12 Motor 2 (Rated Current)
Terminal Extension Functions Control) A13 Motor 2 (Tuning)
A14 Motor 2 (Online Tuning)
E01 - 09 X1 - 9 Terminal Function High Performance Functions A15 Motor 2 (No Load Current)
E10 Acceleration Time 2
H03 Data Initializing (Data Reset) A16 Motor 2 (% R1 Setting)
E11 Deceleration Time 2
H04 Auto Reset (Times) A17 Motor 2 (% X Setting)
E12 Acceleration Time 3
H05 Auto Reset (Reset Interval) A18 Motor 2 (Slip Compensation
E13 Deceleration Time 3
H06 Fan Stop Operation Control 2)
E14 Acceleration Time 4
E15 Deceleration Time 4 H07 ACC/DEC Pattern (Mode Select)
E16 Torque Limiter 2 (Driving) H08 Reverse Phase Sequence Lock
E17 Torque Limiter 2 (Braking) H09 Start Mode
E20 - 24 Y1 - 5 Terminal Function (Rotating Motor Pickup)
E25 Y5 Ry Operation Mode H10 Energy Saving Operation
E30 Frequency Arrival H11 Decel Mode
(Detection Width) H12 Instantaneous Overcurrent
Limiting
Order by Catalog Number or Item Code
BOSTONCONTROLLERS
GEAR
Rated Output
HP Rating Overload, 1 min.
Current (A)
Catalog Item Dimensions Weight
Variable Constant Number Code H x W x D (Inches) (lbs)
Variable Constant Variable Constant
Torque, Torque,
Torque Torque Torque Torque
110% 150%
Stieber Clutch -
Formsprag Clutch - Europe
Overrunning Clutches
and Holdbacks
Heidelberg, Germany
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