Boston gear ACE101V1P0002C User manual

1
User Guide
ACE10 Series
Boston Gear
®
ACE10 SERIES
Adjustable Frequency AC Motor Controller
P-3039-BG

2ACE10UG
TABLE OF CONTENTS
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1. Safety Precautions
1.1 Precautions for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Hardware Instructions and Installation
2.1 Operation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Model No.Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.4 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Dimensions & Location of Terminal Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3. Software Index
3.1 Keypad Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 Malfunction Indications and Countermeasures. . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.4 General Malfunction Examination Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

3
ACE10UG
FOREWORD
To fully use all functions of this AC Drive, and to ensure the safety for its users, please
read through this user's guide in detail. If you have any further questions,
please feel free to contact your local distributor or regional representative.
1.SAFETY PRECAUTIONS
The AC Drive is a power electronic device. For safety reasons, please read carefully those
paragraphs with "WARNING" and "CAUTION" symbols.They are important safety precau-
tions to be aware of while transporting, installating, operating or examining the AC drive.
Please follow these precautions to ensure your safety.
WARNING Personal injury may occur from improper operation.
CAUTION The AC Drive or mechanical system may be damaged by improper
operation.
WARNING
●Do not touch the PCB or components on the PCB after turning off the power before
the charging indicator is turned off.
●Do not attempt to wire circuitry while power is on. Do not attempt to examine compo-
nents and signals on the PCB while the drive is operating.
●Do not attempt to disassemble or modify internal circuitry, wiring, or components of the
controller.
●The grounding terminal of the controller must be grounded properly to 200V class type
III standard.
●This is a product of the restricted sales distribution class according to EN61800-3.
In a domestic environment, this product may cause radio interference in which case the
user may be required to take adequate measures.
CAUTION
●Do not attempt to perform dielectric strength test to internal controller components.
There are sensitive semiconductor devices vulnerable to high voltage in the controller.
●Do not connect the output terminals:T1 (U), T2 (V), and T3 (W) to AC power.
●The CMOS IC on the primary PCB of the controller is vulnerable to static electrical
charges.Do not contact the primary PCB of the controller.
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4
1. SAFETY PRECAUTIONS
1.1 PRECAUTIONS FOR OPERATION
Before turning ON power
CAUTION
Choose the appropriate power source with the correct voltage for the input power
to the AC controller.
WARNING
The input power source must be connected to the L1 and L2 (or L1, L2 or L3) terminals,
and must not be mistakenly connected to the T1, T2 or T3 output terminals.
This may damage the controller when power is turned on.
CAUTION
●Do not attempt to carry the controller by the front of the cover.Securely hold the con-
troller by the heat-sink mounting chassis to prevent the controller from falling, as this may
cause personal injury or damage to the controller.
●Install the controller onto a firm metal base plate or other non-flammable type material.
Do not install the controller onto or nearby any flammable material.
●An additional cooling fan may be needed if several controllers are installed onto
one control panel. The temperature inside an enclosed panel should be below 40
degrees C (104 degrees F) to avoid overheating.
●Turn off the power supply before proceeding to remove or perform any work on any
panel. Carry out installation procedures according to instructions given in order to avoid
an operation malfunction.
●The AC controller is for use on a circuit capable of delivering not more than 5000 RMS
symmetrical amperes.
●The controller is not provided with overspeed protection.
●The controller is only intended for use in a pollution degree 2 environment or equivalent.
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ACE10UG 5
When power is applied:
WARNING
●Do not install or remove input or output controller connections when the power
supply is turned on. Otherwise, the controller may be damaged due to the surge peak
caused by the application or removal of power.
●When momentary power loss is longer than 2 seconds (the larger the horsepower, the
the longer the time), the controller does not have enough storage power to retain control.
Therefore, when power is reapplied, the operation of the controller is based on the
setup of F_10 and the condition of an external switch (FWD/REV button).
This is considered to be a restart in the following paragraphs.
●When the momentary power loss is short, the controller still has enough storage power
to retain control. Therefore, when power is reapplied, the controller will automatically
start operation again, depending on the setup of F_23.
When the controller restarts, the operation is based on the setup of F_10,
and the condition of an external switch (FWD/REV button). The restart operation
is irrelevant with F_23/F_24.
(1) When F_10 = 0, the controller will not start after restart.
(2) When F_10 = 1 and the external switch (FWD/REV button) is OFF, the controller will
not start after a restart command.
(3) When F_10 = 1 and the external switch (FWD/REV button) is ON, the controller will
start automatically after a restart command. For safety reasons, turn off the external
switch (FWD/REV button) after a power loss to avoid possible damage to the machine
and personal injury after sudden regeneration of power.
During Operation:
WARNING
Do not use a separate device to switch the motor ON or OFF during operation. Otherwise,
the controller may experience an over-current breakdown.
WARNING
●Do not remove the controller front cover when the power is ON to avoid personal
injury caused by electrical shock.
●When the automatic restart function is enabled, the motor and machinery will restart
automatically.
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CAUTION
●Do not touch the heat-sink base during operation.
●The controller can be easily operated from a low-speed to high-speed range.
Reconfirm the operating range of the motor and the machinery you are controlling.
●Do not examine the signals on the PCB of the controller during operation.
●All controllers are properly adjusted and set before delivery.
CAUTION
Do not disassemble or examine the controller before ensuring that the power source
is off and the Power LED is not lit.
When performing an examination or maintenance:
CAUTION
The controller environment should be within: -10oC ~ +40oC (14oF ~ 104oF),
with humidity under 95% RH without condensing.
CAUTION
After the removing the shield sticker, the environment should be within: -10oC ~
+50oC (14oF ~ 122oF), with humidity under 95% RH without condensing.
The controller should be free from water dripping and metal dust.
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ACE10UG
2. HARDWARE INSTRUCTIONS AND
INSTALLATION
2.1 OPERATION ENVIRONMENT
The installation site of the controller is very important. It relates directly to the functionality
and the life span of your controller. Carefully choose the installation site to meet the
following requirements:
●Mount the controller vertically
●Environment temp: -10oC ~ +40oC (14oF ~ 104oF) (w/o shield sticker:-10oC ~ +50oC (14oF ~ 122oF))
●Avoid placing the controller close to any heating equipment
●Avoid water dripping and humid environment
●Avoid direct sunlight
●Avoid oil and salty corrosive gas
●Avoid contacting corrosive liquid and gas
●Prevent foreign dust, flocks, and metal scraps from entering the controller interior
●Avoid electrical-magnetic interference (soldering or power machinery)
●Avoid vibration. If vibration cannot be avoided, an anti-vibration mounting device should be
installed to reduce vibration.
●If the controller is installed on an enclosed control panel, remove the shield sticker
located at the top of the controller.This will allow additional airflow and cooling.
External Fan Placement needs to be over the top of the controller.
●For proper Installation of the controller, place the front of the controller facing
front and the top of the controller in the up direction for better heat dissipation.
●Installation must be compliant with the following requirements:
Correct Alignment Wrong Alignment Correct Alignment Wrong Alignment

8ACE10UG
Note: Maximum temperature in the enclosure: 50oC (122oF)
2.2 MODEL NO. IDENTIFICATION
4.72" 4.72"
4.72" 4.72"
2.0"
Ventilation & Installation Direction
Front View Side View
CATALOG NUMBER ITEM CODE TYPE HP RATING VOLTAGE PHASE AMPS
ACE101V1P0002C 43285
Chassis
1/4 115 11.4
ACE101V1P0005C 43286 1/2 2.3
ACE101V1P0010C 43287 14.2
ACE102V1P0002C 43288 1/4
230 11.4
ACE102V1P0005C 43289 1/2 2.3
ACE102V1P0010C 43290 14.2
ACE102V3P0020C 43291 23a
a. Can be operated at single phase without derating.
7.5
ACE102V3P0030C 43292 310.5
ACE104V3P0010C 43293 1460 3 2.3
ACE104V3P0020C 43294 23.8
ACE104V3P0030C 43295 35.2
ACE101V1P0002N4 43296
NEMA 4
1/4 115 11.4
ACE101V1P0005N4 43297 1/2 2.3
ACE101V1P0010N4 43298 14.2
ACE102V1P0002N4 43299 1/4
230
11.4 ACE102V1P0005N4 43300 1/2 2.3
ACE102V1P0010N4 43301 14.2
ACE102V3P0020N4 43302 23a7.5
ACE102V3P0030N4 43303 310.5
ACE104V3P0010N4 43304 1460 3 2.3
ACE104V3P0020N4
43305 23.8
ACE104V3P0030N4
43306 35.2

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ACE10UG
2.3 SPECIFICATIONS
2.3.1 Basic Specifications
ModelChassisACE101V1P0002C ACE101V1P0005C ACE101V1P0010C
NEMA4ACE101V1P0002N4ACE101V1P0005N4ACE101V1P0010N4
SuitableMotorPowerRating (kW)0.2 0.4 0.75 Rated
Motor(HP)1/41/21 OutputCurrent(A)1.4 2.3 4.2 Capacity(KVA)0.53 0.88 1.6 Weight(lbs)Chassis1.7 1.7 1.9
NEMA46.9 6.9 6.9
InputVoltage,MaximumSinglePhase100-120VAC(+10%,-15%),50/60 Hz(+/-5%) OutputVoltage,MaximumThree Phase200-240 VAC(Proportionaltoinputvoltage) DimensionsW*H*D(Inches)Chassis2.83 x5.16 x4.65
NEMA45.54 x8.49 x7.19
EMCSpecification WithoutFilter
ModelChassisACE102V1P0002C ACE102V1P0005C ACE102V1P0010C ACE102V3P0020C ACE102V3P0030C
NEMA4ACE102V1P0002N4ACE102V1P0005N4ACE102V1P0010N4ACE102V3P0020N4ACE102V3P0030N4
SuitableMotorPowerRating (kW)0.2 0.4 0.75 1.5 2.2 Rated
Motor(HP) 1/41/2123 OutputCurrent (A) 1.42.34.27.510.5 Capacity (KVA) 0.530.881.62.94 Weight(lbs)Chassis1.7 1.7 1.9 4.3 4.6
NEMA47.1 7.1 7.1 13.5 13.5
InputVoltage,MaximumSinglePhase200-240 VAC(+10%,-15%),50/60 Hz(+/-5%)SingleorThree Phase200-240 VAC
(+10%,-15%),50/60 Hz(+/-5%)
OutputVoltage,MaximumThreePhase200-240 VAC(Proportionaltoinputvoltage) DimensionsW*H*D(Inches)Chassis2.83 x5.16 x4.65 4.65 x5.63 x6.77
NEMA45.54 x8.49 x7.19 9.13 x11.61 x8.32
EMCSpecification Class A(Singlephasefilterbuiltin)
ModelChassisACE104V3P0010C ACE104V3P0020C ACE104V3P0030C
NEMA4ACE104V3P0010N4ACE104V3P0020N4ACE104V3P0030N4
SuitableMotorPowerRating (kW)0.75 1.5 2.2 Rated
Motor(HP) 123 OutputCurrent (A) 2.33.85.2
Capacity (KVA) 1.72.94
Weight(lbs)Chassis3.1 3.1 3.2
NEMA412.8 13.3 13.5
InputVoltage,MaximumThree Phase380-480 VAC(+10%,-15%),50/60 Hz(+/-5%) OutputVoltage,MaximumThree Phase380-480 VAC(Proportionaltoinputvoltage) DimensionsW*H*D(Inches)Chassis4.65 x5.63 x6.77
NEMA49.13x11.64 x8.32
EMCSpecification Class A(Three phasefilterbuiltin)

10 ACE10UG
2.3.2 Functional Specifications
Item Specification
Input Signal Type PNP type (SOURCE) input (External 24 VDC input is allowed)
Control Method Sinusoidal wave PWM control
Frequency
Control
Frequency Range 1 - 200 Hz
Resolution Setting Digital: 0.1 Hz (1 - 99.9 Hz); 1 Hz (100 - 200 Hz)
Analog: 1 Hz / 60 Hz
Keypad Setting Direct setup by buttons
External Signal Setting 0 - 10V, 4 - 20mA, 0 - 20mA
Other Function Frequency upper and lower limit
General
Control
Carrier Frequency 4 - 16 KHz
Accel/Decel Time 0.1 - 999 seconds
V/F Pattern 6 patterns
Torque control Torque boost level adjustable (manual torque boost)
Multi-functional Input 2 point, to be used as multi-speed 1(Sp. 1) / multi-speed 2(Sp. 2)
/ Jog / External emergency stop / External bb / Reset
Multi-functional Output 1a relay terminal, to be set up as Fault / Running / Frequency
Braking Torque About 20%. 20 - 100% with built -in braking transistor
Other Function Decelerate or free run stop, Auto reset, DC braking frequency /
Voltage / Time can be set up by constants
Display Three LED’s display frequency / drive parameter / fault record /
program version
Operating Temperature -10 - +40°C (14 - 104°F) (without shield sticker: -10 - +50°C
(14 - 122°F))
Humidity 0 - 95% RH non-condensing
Vibration Under 1G (9.8 m/s2)
EMC Specification EN5008-1, EN5008-2, EN50082-1, EN50082-2, EN50178
UL UL508C
Protection
Function
Overload 150% for 1 minute
Over Voltage DC voltage > 410V(100/200 series); DC voltage > 800V(400
series)
Under Voltage DC voltage < 200V(100/200 series); DC voltage < 400V(400
series)
Momentary Power Loss 0 - 2 seconds: The drive can be restarted using speed search
feature.
Stall Prevention During Acceleration / Deceleration / Constant speed
Output Short-circuit Electronic circuitry protection
Grounding Fault Electronic circuitry protection
Other Function Heat sink overheat protection, Current limit
Installation Mounting screw or DIN rail (option)

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ACE10UG
2.3.3 Suitable Optional and Wiring Specifications
Molded-Case Circuit Breaker / Magnetic Contact
●Warranty does not apply to damage caused by the following situations:
(1) Damage to the controller caused by the lack of appropriate molded-case circuit breaker or
when a circuit breaker with too large of capacity is installed between the power supply and
the controller.
(2) Damage to the controller caused by a magnetic contact, phase advancing capacitor, or
surge-protector installed between the controller and the motor.
●Use a three-phase squirrel-cage induction motor with appropriate rating.
●If the controller is used to drive more than one motor, the total motor current must be less
than the controller current rating. Additional thermal overload relays must be installed in
series with each motor.Use the Fn_18 at 1.0 times the rated value specified on the motor
nameplate at 50Hz, 1.1 times the rated value specified on the motor nameplate at
60Hz.
●Do not install phase advancing capacitors, LC, or RC components between the controller and motor.
Controller Rating 1.4/2.3A, 115/230V 4.2/7.5A, 115/230V 10.5A, 230V 2.3/3.8/5.2A, 460V
Molded-case circuit breaker 15A 20A 30A 15A
PrimaryCircuit Terminal (TM1)
Wire dimension
(#14AWG) 2.0mm2
* Terminal L3 is on three Terminal screwM3
Wire dimension
(#14AWG)
2.0m m2
Terminal screw
phase controllers only. M3/M4
Wire dimension
3.5mm2
Terminal screw
M4
Wire dimension
3.5mm2
Terminal screw
M4
Signal Terminal (TM2)
1~11 Wire dimension 0.75mm2 (#18 AWG), Terminal screw M3
Use copper conductorsonly. Sizefield wiring based on 80 degrees C wire only..
T3
T1 T2
L1 L2 L3*

12 ACE10UG
2.3.4 Application and precautions of peripherals
From the power source:
●Be sure the power source is rated correctly to prevent damaging the
controller.
●A power disconnect or circuit breaker must be installed between the AC power supply
and the controller.
Molded-case circuit breaker:
●Use a correctly sized circuit breaker to protect the controller.
●Do not use the circuit breaker to switch power ON or OFF to the controller. The circuit breaker
should be used only to provide protection.
Leakage circuit breaker:
●An earth leakage circuit breaker should be added to prevent false operation cause by
leakage current, and to ensure personal safety.
Magnetic contactor:
●A magnetic contactor can usually be omitted.However, to utilize external control,
automatic restart, or braking the controller, a magnetic contactor must be added at the pri-
mary side.
●Do not use a magnetic contactor to switch power ON or OFF to the controller.
Power improvement AC reactor:
●If a large capacity power source is applied (over 600 KVA), an additional AC reactor may be
added to improve power factor.
Controller:
●The power supply input terminals (L1, L2 and L3) are not sensitive to phase sequence.They
can be arbitrarily connected.Also, their connections may be interchanged.
●Output terminals T1, T2, and T3 should be connected to motor terminals U,V, and W, respectively.
If the motor turns in the opposite direction of the controller command, simply
exchange two of the three motor connections to correct this problem.
●Output terminals T1, T2, and T3 must not be connected to a power source. Otherwise,
the controller may become damaged.

13
5740
●Grounding circuitry must not be formed when grounding several controllers together.
Use appropriate wire with correct diameter for primary power cir-
cuitry and control circuitry in accordance with electrical regulations.
P R
L1(L)(R)
L2 (S)
L3 (N)(T)
FWD
REV
SP1
RST
12V
+10V
VIN
(0~10V/0~20mA/4~20mA)
0V(FM–)
FM+
Braking
Resistor (Option)
SW1
1
2
3
(U)T1
(V)T2
(W)T3
1
2
CON2
AC Input
IM
}
Trip Relay
Grounding
3
4
6
7
5
{
Multi-Function
Inputs
8
9
10
11
FM
Speed Pot 5kΩ
0~10V
Test Points
2.4 WIRING DIAGRAMS
TM2
FWD
REV
SP1
RST
0V
3
4
6
7
10
+
24V
–
External 24V supply
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ACE10UG

ACE10UG
Controller Terminal Descriptions
Primary Circuitry Terminal Block (TM1) description
Control Circuitry Terminal Block (TM2) description
Terminal Symbol Function Description
L1/L (R)
L2 (S)
L3/N (T)
Primarypower source(line voltage) input to the controller
Single phase: L1/L2
Three phase: L1/L2/L3
P
R1 - 3HP, 460V)
External braking resistor terminal (Onlyfor 2 & 3HP, 230V &
T1 (U)
T2 (V)
T3 (W)
Controller output tothe motor
Tightening torque forTM1 is 1 LB-FTor 12 LB-IN(1/4HP - 1/2HP, 115V & 1/4 - 1HP, 230V).
Tightening torque forTM1 is 1.3LB-FTor16 LB-IN(2 - 3HP, 230V & 1 - 3HP, 460V).
* Wirevoltageratingmust be a minimum of300V(200V series)/600V(400V series).
Terminal Symbol Function Description
1
2
TRIP
RELAY
Fault relayoutput terminal.Multifunction output terminal (refer to F_21)
Connection point rated 250VAC @ 1A (30VDC @ 1A)
3FWD(F
W)
4 REV (RE) Operation control terminals (refer to F_03)
5+12V(12) Common point of terminals 3, 4, 6 & 7
6SP1(
SP)
7 RESET(RS) Multifunction input terminals (refer to F_19)
8+10VPower terminal for potentiometer (Pin 3)
9Analog input wire
Wiper
Analog frequencysignalinput terminal (Pin 2 of
potentiometer or positive terminal of 0~10V / 4~20mA
/ 0~20mA)
10 0V(FM -) Analog common point Analog signal common point (Pin 1 of potentiometer
or negative terminal of 0~10V / 4~20mA / 0~20mA)
11 FM+ Analog output positive
connection point Analog frequency signal output terminal
Output terminal signalis 0~10VDC/Fn6
Tightening torque forTM2 is 0.42 LB-FTor5.03 LB-IN.
* Wirevoltageratingmust be a minimum of300V.
* Control wiring should notbe run in the same conduit orraceway with power or motor wiring.
* Single Inputand Output Terminals (TM2):Ratings are all Class 2.
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ACE10UG

Unit:inches
5.20 4.57 5.16 0.32 4.65 2.40 2.83
SWITCH 1 External signal type
0~20mA analog signal (When F_11 is set to 1)
4~20mA analog signal (When F_11 is set to 2)
0~10 VDC analog signal (When F_11 is set to 1)
SW1 function description
2.5 DIMENSIONS & LOCATION OF TERMINAL BLOCK
1/4-1HP, 115/230V:
NOTE: For safety reasons, we strongly recom-
mend users to remove the M4 grounding screw,
then screw the enclosed "metal frame ground-
ing terminal" onto the same location to make a
grounding bar to ensure good earth protection.
16 ACE10UG

2-3HP, 230V & 1-3HP, 460V:
Unit:inches
A B C D EFG
5.63 5.02 5.63 0.32 6.77 4.25 4.65
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ACE10UG

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117.35 (4.62)
133.60 (5.26)
188.98 (7.44)
204.74 (8.06)
133.10 (5.24)
173.48 (6.83)
NEMA 4 - 1/4-1HP, 115/230V:
Operator controls shown are optional
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UNIT: mm (Inches)
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18 ACE10UG

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NEMA 4 - 2-3HP, 230V & 1-3HP, 460V:
Operator controls shown are optional
ACE10UG 1919
19
(9.08)
(9.06)
(8.27)
(11.42) (10.81)
(11.58)
(7.30)
(6.36)
(2.17)
(0.20) (6.88)

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



 !
"
#



 


  

(S(Single Phase Input Shown)













 





 







 !
"
#


TYPICAL NEMA 4 CONNECTIONS AND EMC MOUNTING:
20
ACE10UG