AUTOMATIONDIRECT GSD1 Series DC Drives User Manual

GSD1 Series DC Drives

User Manual

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PUBLICATION HISTORY

GSD1 DC DRIVES USER MANUAL OVERVIEW

OVERVIEW OF THIS PUBLICATION

The IronHorse GSD1 Series DC Drives User Manual describes the installation, configuration, and methods of operation of the GSD1 Series DC Drives.

All information contained in this manual is intended to be correct. However, information and data in this manual are subject to change without notice. Automation Direct (ADC) makes no warranty of any kind with regard to this information or data. Further, ADC is not responsible for any omissions or errors or consequential damage caused by the user of the product. ADC reserves the right to make manufacturing changes which may not be included in this manual.

WHO SHOULD READ THIS USER MANUAL

This manual contains important information for those who will install, maintain, and/or operate any of the GSD1 Series DC Drives.

TECHNICAL SUPPORT

BY TELEPHONE: 800-633-0405 (MON.–FRI., 9:00 A.M.–6:00 P.M. E.T.) ON THE WEB: WWW.AUTOMATIONDIRECT.COM

Our technical support group is glad to work with you in answering your questions. If you cannot find the solution to your particular application, or, if for any reason you need additional technical assistance, please call Technical Support at 800-633-0405. We are available weekdays from 9:00 a.m. to 6:00 p.m. Eastern Time.
We also encourage you to visit our web site where you can find technical and non-technical information about our products and our company. Visit us at www.automationdirect.com

SPECIAL SYMBOLS

NOTE: When you see the “notepad” icon in the left-hand margin, the paragraph to its immediate right will be a special note.

WARNING: WHEN YOU SEE THE “EXCLAMATION MARK” ICON IN THE LEFT-HAND MARGIN, THE PARAGRAPH TO ITS IMMEDIATE RIGHT WILL BE A WARNING. THIS INFORMATION COULD PREVENT INJURY, LOSS OF PROPERTY, OR EVEN DEATH (IN EXTREME CASES).

IRONHORSE GSD1 SERIES DC DRIVES GENERAL INFORMATION

STANDARD FEATURES

• Provides smooth variable speed capability for mobile equipment.
• Automatic compensation holds motor speed steady even if the load varies or battery voltage declines.
• Adjustable maximum speed, minimum speed, current limit, IR compensation, and motor acceleration.
• Inhibit terminal permits optional start-stop without breaking battery / power lines.
• Speed potentiometer, knob, and dialplate included.
• Enclosed models (GSD1-48-10N4X, GSD1-24-15N4X-R) are rated NEMA 4X.

Carefully check the DC Drive for shipping damage. Report any damage to the carrier immediately. Do not attempt to operate the drive if visible damage is evident to either the circuit or to the electronic components.

SELECTION AND SPECIFICATIONS

DIMENSIONS

inches [mm]

INSTALLATION AND WIRING

WIRING

Refer to the following wiring diagrams for proper connection of DC Voltage, Armature, and Speed Pot wiring to the DC drive.

BASIC WIRING DIAGRAMS

Speed pots can be replaced by 0–10V analog signals (PLC, etc.). For 0–10 VDC input signal, please refer to “Operational Description: 0 to 10 VDC Analog Reference Signal to GSD1” on page 11.”

GSD1-24-15N4X-R BASIC WIRING DIAGRAM

REVERSING WIRING DIAGRAMS

OPERATIONAL DESCRIPTION: 0 TO 10 VDC ANALOG REFERENCE SIGNAL TO GSD1

IronHorse GSD1 drives, though advertised to work with a 0 to 10 volt reference, exhibit an offset in output response when used in this manner. With 0 to 10 VDC connected to the GSD1 drive, output voltage is zero volts until the analog reference value reaches two volts, where the GSD1 drive output voltage will begin to rise. As the analog reference voltage rises, the GSD1 drive output voltage rises in proportion and linear to the reference. At five volts reference the GSD1 drive output is 50%, and at 10 volts reference the output is 100% of the expected voltage. Adjustments to min and max speed have no effect on the observed behavior.

The installation of a 4.7kΩ resistor across Pot Hi (P2-1) and Pot Lo (P2-3) helps with GSD1 drive output voltage, but is NOT a perfect solution. With the resistor installed, GSD1 drive output voltage is proportional to the lower reference voltage with a linear output response to midscale, where 1 to 5 volts reference equals 10% to 50% output. The problem is that linearity suffers as reference voltage increases. If the drive is linear from 1 to 5 volts then output voltage is low at the top, where 10 volts reference equals roughly 90% output. If adjustments are made to provide 100% output at the top, then the drive ignores the falling reference voltage and runs fast at midscale, where 5 volts reference equals 55% output.

All GSD1 drives have some dead band built into the speed pot circuit which, when a speed pot is used, can be tuned out using the MIN trim pot. The physical connection of a speed pot also provides a current path so that the MIN trim pot is active in the circuit. When using a reference signal connected +Signal to Wiper and -Signal to Pot Lo, the current path for the MIN trim pot is lost and therefore no longer in the circuit; thus the need for a 4.7–5 kΩ resistor from Pot Hi to Pot Lo.

With a 0–10 VDC reference signal input, and with the MIN trim pot active, the MIN trim pot can be turned up to reduce or eliminate the dead band in the bottom end of the signal. However, this also has the effect of shifting the reference signal to effectively be a 2–12 VDC signal. The top of the reference (10–12 VDC) is ignored and the drive response becomes non-linear.

For most applications this is not an issue, as most do not operate in the bottom or top 20% of reference signal / speed range. However, for those applications that do, another fix is to scale the reference signal at the source to keep the effective reference signal always in the 0–10 VDC range. Changing from a 0–10 to a 0–8 VDC signal at the source, and turning up the MIN trim pot ~2V to offset dead band at the bottom, will operate the motor from 0–100% speed with a more linear response.

There is NO signal conditioning solution for the performance issue described in the GSD1 drive.

TRIM POT ADJUSTMENT

Before the power is applied, set the voltage selection jumper to the correct voltage. An incorrect jumper setting will not damage the drive, but will affect the trim pot adjustments. The speed potentiometer and trim pots should be preset as follows:

TRIM POT PRESET

1. Preset Speed pot fully CCW.
2. Preset MAX trim pot CW 1/2 way.
3. Preset CURRENT LIMIT trim pot fully CW.
4. Preset MIN trim pot fully CCW.
5. Preset ACCEL trim pot CW 1/2 way.
6. Preset IR trim pot fully CCW.

DC power can now be applied to the system and the DC Drive adjusted as follows:

TRIM POT ADJUSTMENT

1. Increase the MIN trim pot CW until just before reaching an output voltage (deadband), or until the desired minimum speed is reached.

2. Turn the Speed pot fully CW and adjust the MAX trim pot until the desired maximum speed is
   reached.

3. Adjust the ACCEL trim pot to achieve the desired soft start time.
   (CW rotation will increase accel time.)

4. Rotate the CURRENT LIMIT trim pot fully CCW. Apply a full load to the motor. While motor is
   stalled, adjust the CURRENT LIMIT trim pot CW until a desired current setting is obtained.
   (Approximately 125% of rated motor current is recommended.)

5. For 10A models GSD1-48-10C:
   Set the Speed pot to approximately 50%, and note the motor RPM. Load the motor to normal load condition and adjust the IR trim pot CW until motor RPM is equal to the unloaded speed.
   For 15A and 20A models GSD1-24-15N4X-R and GSD1-48-20C:
   Adjust the IR trim pot CW 1/2 way. If the motor speed is inconsistent (jumpy), rotate the IR trim pot CCW until the motor rotation becomes stable.

6. If the voltage selection jumper setting is changed, repeat Trim Pot Preset and Trim Pot Adjustment.

TROUBLESHOOTING

If a newly installed DC Drive will not operate, it is likely that a terminal connection is loose. Check the terminal connections and ensure that they are secure and correct. If the drive is still inoperative, refer to the Troubleshooting Table.

Literature Number: LT164

Drawing Number: A-5-4009D

IronHorse GSD1 DC Drives User Manual – 3rd Ed. Rev A – 02/24/2021

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