The Velocio Ace series represents a fundamental rethinking of what a programmable logic controller can be. Measuring just 2.5 by 2.5 by 0.5 inches and weighing under 90 grams, it is widely recognized as one of the smallest PLCs on the global market. Its diminutive size, however, belies a powerful and flexible automation platform capable of handling everything from simple logic control to complex multi-axis motion and PID process control. A standard USB Mini-B cable provides both programming connectivity and power, eliminating the need for proprietary cables, external power supplies, or specialized drivers. This simplicity makes the Ace PLC accessible to students, hobbyists, and professional automation engineers alike.

The Ace series is available in a wide range of models, from the entry-level Ace 11 (6 digital in, 6 digital out) to the advanced Ace 7092 and 7096 series (6 D in, 12 D out, 4 analog in, 2 analog out, 4 thermocouple inputs, and 2 RS232 ports). All models share a common set of powerful features: digital inputs accept any DC voltage between 3 and 30VDC; digital outputs are sinking transistors capable of handling up to 300mA per point and supporting PWM across all channels; and analog inputs offer 12-bit resolution with configurable ranges of 0-5VDC, 0-10VDC, or 0-20mA. Select models incorporate 16-bit differential inputs for direct connection of J, K, N, and T type thermocouples. For applications requiring additional I/O protection or higher power switching, Velocio offers a family of terminal boards including opto-coupled inputs, relay outputs, and transistor outputs, all of which connect to the Ace PLC via pre-wired cables and mount on standard 35mm DIN rails.

Motion control is a standout capability of the Ace platform. Through the vBuilder software environment, users can configure high-speed pulse and direction outputs for controlling up to three stepper or servo motors simultaneously. Digital inputs can be configured for quadrature pulse counting or high-speed single-phase counting, enabling precise position feedback for closed-loop motion applications. A built-in PID function block provides the foundation for temperature control, pressure regulation, and other process control tasks. All motion parameters, including acceleration and deceleration profiles, are configured graphically within vBuilder, dramatically simplifying what would otherwise be a complex programming task.

The software ecosystem is arguably the Ace PLC's greatest differentiator. Velocio provides two free software applications: vBuilder for programming and vFactory for HMI creation. vBuilder supports both traditional ladder logic programming and an innovative flowchart-based development environment that allows engineers to visualize control sequences graphically. Subroutines, user-defined objects, and linked subroutines enable modular, reusable code development—concepts typically reserved for much more expensive PLC platforms. The software provides real-time warnings and errors during development, eliminating surprises at deployment. Once programmed, users can connect the Ace PLC to vFactory, which automatically discovers all tags, distinguishes read-only from writable values, and provides 12 different tools for building custom operator interfaces with graphs, numeric displays, labels, and value adjustment controls. The Ace PLC also supports custom ASCII communications over its serial ports, enabling direct integration with barcode scanners, RFID readers, GPRS modems, and other serial devices. Modbus ASCII/RTU protocols are supported on RS232/RS485-equipped models.

Installation flexibility is another hallmark of the Ace design. Every Ace PLC ships with a super-strong 3M adhesive strip on its underside, capable of bonding to painted metals, plastics, and glass—the same material used to attach skyscraper windows to their frames. For more traditional industrial mounting, an optional DIN rail adapter and screw-mount bracket are available. The PLC operates reliably across an extreme temperature range from -30°C to +70°C, with power consumption as low as 0.18 watts in typical applications. This combination of wide temperature tolerance, minimal power draw, and tiny footprint makes the Ace PLC exceptionally well-suited for embedded applications, remote monitoring stations, mobile equipment, and Internet of Things (IoT) edge devices.

Applications

The Velocio Ace series is deployed across a remarkably diverse range of industries and applications:

• Embedded Automation: Core intelligence for custom OEM products, providing PLC reliability with embedded system flexibility.
• IoT and Remote Monitoring: Low-power, wide-temperature operation combined with serial communication for GPRS/RTU connectivity.
• Machine Control: Small packaging machinery, labeling systems, pick-and-place mechanisms, and conveyor control.
• Motion Systems: Up to 3-axis stepper/servo control for camera sliders, telescope mounts, CNC peripherals, and laboratory automation.
• Home Automation: Lighting control, HVAC zone management, irrigation systems, and custom smart home projects.
• Automated Test Equipment: Custom test fixtures, burn-in racks, and quality assurance stations.
• Educational and Hobbyist Projects: PLC training, robotics competitions, and maker projects with minimal cost barrier.

Technical Specifications