Automationdirect.com IronHorse GSD Series User manual

Page 1IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
™
GSD Series DC Drives Accessory
GSDA-DP-D PROGRAMMABLE DIGITAL
CLOSED / OPEN LOOP MOTOR SPEED CONTROL
SYSTEM FOR AC AND DC DRIVES User Manual
User Manual Number: GSDA-DP-D-User-M

Page 2 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
~ WARNING ~
Thank you for purchasing automation equipment from Automationdirect.com®, doing business as Automation-
Direct. We want your new automation equipment to operate safely. Anyone who installs or uses this equipment
should read this publication (and any other relevant publications) before installing or operating the equipment.
To minimize the risk of potential safety problems, you should follow all applicable local and national codes that
regulate the installation and operation of your equipment. These codes vary from area to area and usually change
with time. It is your responsibility to determine which codes should be followed, and to verify that the equipment,
installation, and operation is in compliance with the latest revision of these codes.
At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical Code,
and the codes of the National Electrical Manufacturer’s Association (NEMA). There may be local regulatory or
government offices that can also help determine which codes and standards are necessary for safe installation and
operation.
Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes
and standards. We do not guarantee the products described in this publication are suitable for your particular
application, nor do we assume any responsibility for your product design, installation, or operation.
Our products are not fault-tolerant and are not designed, manufactured or intended for use or resale as on-line
control equipment in hazardous environments requiring fail-safe performance, such as in the operation of
nuclear facilities, aircraft navigation or communication systems, air traffic control, direct life support machines,
or weapons systems, in which the failure of the product could lead directly to death, personal injury, or severe
physical or environmental damage (“High Risk Activities”). AutomationDirect specifically disclaims any
expressed or implied warranty of fitness for High Risk Activities.
For additional warranty and safety information, see the Terms and Conditions section of our catalog. If you have
any questions concerning the installation or operation of this equipment, or if you need additional information,
please call us at 770-844-4200.
This publication is based on information that was available at the time it was printed. At AutomationDirect we
constantly strive to improve our products and services, so we reserve the right to make changes to the products
and/or publications at any time without notice and without any obligation. This publication may also discuss
features that may not be available in certain revisions of the product.
Trademarks
This publication may contain references to products produced and/or offered by other companies. The product
and company names may be trademarked and are the sole property of their respective owners. AutomationDirect
disclaims any proprietary interest in the marks and names of others.
Copyright © 2019 Automationdirect.com®Incorporated
All Rights Reserved
No part of this manual shall be copied, reproduced, or transmitted in any way without the prior, written consent of
Automationdirect.com®Incorporated. AutomationDirect retains the exclusive rights to all information included
in this document.
Publication History
Issue Date Description
1st Edition July 2019 Initial Publication
1st Edition Rev. A October 2019 Revised accessory descriptions

Page 3IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
Contents
~ WARNING ~                                                              2
Trademarks                                                                 2
Publication History                                                            2
GSDA-DP-D Programmable Digital Motor Speed Control Manual Overview                           4
IronHorse GSDA-DP-D Motor Speed Control General Information                                5
Specifications                                                                6
Mechanical Installation                                                         7
Wiring                                                                    9
Basic Operating Information                                                      11
Detailed Configuration Instructions                                                 14
GSDA-DP-D Software Parameters                                                   19
GSDA-DP-D Software Parameter Descriptions                                            23
Application Examples                                                          36
Troubleshooting                                                             39

Page 4 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
GSDA-DP-D Programmable Digital Motor Speed Control Manual Overview
Overview of this Publication
The IronHorse GSDA-DP-D manual describes the installation, configuration, and operation of the
GSDA-DP-D programmable digital closed/open loop motor speed control system for AC and 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. AutomationDirect (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 Data Sheet
This manual contains important information for those who will install, maintain, and/or operate the
GSDA-DP-D motor speed control unit.
Technical Support
By Telephone: [phone] (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 770-844-4200. 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
When you see the “notepad” icon in the left-hand margin, the paragraph to its
immediate right will be a special note.
When you see the “exclamation mark” icon in the left-hand margin, the paragraph to its immediate right
Will be aWarning. this information could prevent injury, loss of property, or even death (in extreme
cases).

Page 5IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
IronHorse GSDA-DP-D Motor Speed Control General Information
The GSDA-DP-D motor speed control is a compact, microprocessor-based unit capable of being either
field or factory configured for a number of motion control needs. The control is designed around a
velocity form PID algorithm, and provides a DC speedpot signal to an external drive. A flexible open-loop
mode is also available for applications where using a speed pickup is not practical or desired. The
GSDA-DP-D is easily configured to operate as a digital speed controller, time-based process controller,
or as a ratiometric follower controller in master-slave systems. Featuring a modular bus expansion slot
architecture, it is ideal for volume OEM adjustable speed control applications requiring specialized inputs
and outputs. The unique modular expandability makes the GSDA-DP-D ideal for applications such as:
• Water and Waste Treatment Systems
• Conveyor Oven Controllers
• Synchronized Conveyor Lines
The GSDA-DP-D durable 1/8 DIN NEMA 4/4X aluminum housing can be easily mounted in a panel or
control cabinet.
Carefully check the unit for shipping damage. Report any damage to the carrier
immediately. Do not attempt to operate the speed control unit if visible dam-
age is evident to either the housing or to the electronic components.
Standard Features
• Microprocessor-based design allows for incredible exibility to suit your process control needs.
• Modular-bus expansion makes it possible to accomodate a wide variety of I/O.
• Digital closed-loop algorithm ensures accuracy of plus or minus 1/2 RPM of set speed or equivalent.
• Digital open-loop operation available, where a speed pickup is impractical or undesired.
• Non-volatile memory stores settings without batteries, even when power has been removed.
• Factory or eld programmable via front-panel keypad.
• Many adjustable settings include min, max, accel, decel, display options, alarm options, and more.
• Internal program-enable jumper selectively prevents tampering with unit’s conguration.
• Universal power supply accepts line voltages inputs from 85-265VAC @ 50-60Hz without switches or
jumpers. The unit automatically adjusts as needed.
• Input power transient voltage protection prolongs the unit’s life in harsh industrial environments.
• Flexible user inputs support Inhibit, Emergency-Stop, and Jog functionality.
• Speed pickup input compatible with a variety of signal input types including: Hall-effect pickups,
photoelectric, TTL, etc. Note: Open collector devices must be capable of sinking at least 3mA.
• Self-contained power supply for external speed pickups, limited to 5V @ 50mA.
• One programmable alarm output with Form C contacts. A second alarm output available on the
GSDA-AI-A8 if installed.
• 1/8 DIN durable aluminum housing for panel mounting.
• Large 4-digit, 1/2” LED display, with user-settable decimal point (colon displayed in Time mode).
• Polycarbonate membrane and gasket (included) meet NEMA 4X standards when used with NEMA 4X
enclosures.
• Wide operating ambient temperature range of -10 ºC to 45 ºC (14 ºF to 113 ºF).
• Multiple operating modes are available in closed-loop operation, including:
• Master, Rate Mode – Controls in time unit such as HH:MM, MM:SS, SS:TT, or other unit.
• Time Mode – Displays in time units such as HH:MM, MM:SS, SS:TT, or other units.
• Follower Mode – Controls in percentage of master rate. This mode allows the control to precisely
follow the actions of a master process.

Page 6 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
Specifications
GSDA-DP-D – Specifications
Electrical
Line Input Voltage 85–265 VAC
Line Input Frequency 48–62 Hz
Signal Input Voltage Range 5VDC to 24VDC (square wave,
referenced to P1-6 COMMON)
Speed Pickup Input Frequency Range (S1 and S2 Inputs) 0 – 600,000 pulses per minute @ 5V
square wave
Display Range 0.001 – 9,999
Units of Operation User programmable, any unit
Sensor / Pickup Power Supply 5V @ 50mA
Isolated Alarm Relay Output Rating 250VAC @ 5A
Input Voltage Span Minimum / Maximum 2VDC / 24VDC
Potentiometer “Wiper” Output Voltage Span* Input Voltage Span minus 100mVDC
Mechanical
Display Type LED, Red, 4-Digit, 1/2 inch Height
Housing Type (with supplied gasket in NEMA 4X panel) 1/8 DIN NEMA 4X
Connector Style 12-position 5mm European Style
Terminal Block Torque Setting 4.4 lb·in max [0.5 N·m]
Faceplate Material Polycarbonate with polycarbonate
overlay
Housing Material Aluminum
Weight 15.30 oz [433.86g]
Environmental Operating Temperature Range -10 °C to 45 °C [14 °F to 113 °F]
Operating Humidity Range 95% non-condensing
* Example: Input Voltage Span = 12VDC (0 to 12 VDC Range), Pot Wiper Output Voltage Span = 11.9VDC, (0VDC
+50mVDC offset = 0.05VDC) to (12VDC – 50mVDC = 11.95VDC) = (11.95VDC – 0.05VDC = 11.90VDC)
Available Accessories
Recommended Accessory Description Pulses per
Revolution
GSDA-PU2E/PU2R Hall-Effect Pickup, Single Channel 1 / 10 / 20
GSDA-AI-A8 Input/Output option card -
GSDA-CM-8 Serial communications/Analog Input option card -

Page 7IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
Mechanical Installation
Do not mount GSDA-DP-D digital potentiometer where ambient temperature is out-
side the range of -10 to 45 °C (14 to 113 °F).
Panel Mounting
PANEL MOUNTING GASKET
(WITH THE ADHESIVE SIDE OF
GASKET FACING THE CUSTOMER
MOUNTING PANEL)
CUSTOMER
MOUNTING PANEL
(HOLE CUT-OUT FOR CONTROL
HOUSING APPROXIMATELY
3.622" WIDE BY 1.770" HIGH)
GSDA-DP-D
Control
SUPPLIED WITH EACH CONTROL:
1) GASKET
2) (2) 6-32 X 3/4 PANHEAD BLACK OXIDE STAINLESS SCREWS
3) (2) #6 NUT WITH LOCKWASHER
Cut-out and Mounting Dimensions
Dimensions (in [mm])
3.62
[91.9]
HOUSING DEPTH
4.625 [117.5]
PANEL CUT-OUT
1.77 [45.0]
4.00
[101.6]
4.00
[101.6]
.140
[3.6] x 2
0.885 [22.5]
Tach Ite
m
ValuPage Tach
Ite
m
ValuPage
ENTER
Tach Item ValuAuto
Alm1 Alm2Man Error
---
GSDA-DP-D Dimensions
5.00
[127.0]
4.625
[117.5]
2.289
[58.1] 1.656
[42.1]

Page 8 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
GSDA-PU2E and GSDA-PU2R Pickup Installation (Required for Closed-Loop Only)
The GSDA-PU2E and GSDA-PU2R pickups are an economical way to monitor motor speed. The
GSDA-PU2E is designed for indoor use and the GSDA-PU2R for wash down or outdoor use. Both
provide one, ten or twenty pulses per revolution.
Their design provides for ease of installation in otherwise difficult to reach areas. They operate from a
+5V power supply, producing a 5 volt square wave whose frequency is proportional to speed. This signal
is fed into the GSDA-DP-D speed control as a speed or position reference for the microprocessor.
Caution: The GSDA-PU2E/GSDA-PU2R cable should not be grouped with other wires
or cables. For applications with GSDA-PU2E/GSDA-PU2R wire over 6 feet long,
or noisy environments, a shielded cable is recommended. Connect the shield to
the common terminal on the GSDA-DP-D. leave the shield on the GSDA-PU2E/
GSDA-PU2R end floating.
Step 1 Tap motor shaft end for 10-32 screw, 1/2”
deep
• No other screws are necessary, as the cord will keep the
unit from rotating.
• The PU gives a high signal when the North Pole in the
magnet crosses the hall-effect transistor. The signal is
switched off when the South Pole crosses the hall-effect
transistor. The result is a square wave whose frequency
is proportional to the speed of the shaft on which the
PU is mounted. The number of North/South Pole pairs
directly affects the output.
Step 2 Remove cap from screw
Step 3 Remove black dust cover
Step 4 Install and tighten PU assembly
Step 5 Secure black cover onto housing
dust
cover
3/16"
spacer
male/female
adapter
(optional)
tapped
motor
shaft
PU
bearing
flat
washer
10-32
screw
magnetic
disc
black wire
common
red wire
+VDC
white wire
signal
(note: can be used
on +5 through +24
volt power supply)
Note: All other Ironhorse, MTPM,
TENV motors are NOT drilled and
tapped for use with encoders.
The following Ironhorse, MTPM
motors are drilled and tapped 10-32
for use with these encoders:
MTPM-P75-1L18 & 1M18,
MTPM-001-1L18 & 1M18,
MTPM-1P5-1L18 & 1M18,
MTPM-002-1M18

Page 9IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
GSDA-PU2x Parts List
Notes:
1. Magnetic discs are included with the
kit and are NOT available separately.
2. Use of the threaded adapter is
optional, depending on the distance
between the end of the motor shaft
and the fan shroud. If the supplied
10-32 screw and 3/16” spacer are
insufficient in length to bridge that
gap, the threaded adapter should
be used in addition to the screw and
spacer.
3. Torque 10-32 screw to 10-12 in-lbs.
4. Use thread locker on 10-32 threaded
connection
Dimensions
(1) PU sensor body with 6’ cord and dust
cap 1.60
2.40
0.875
72.00
(1) Magnetic disc1(#2, 1PPR)
(1) Magnetic disc1(#20, 10PPR)
(1) Magnetic disc1(#40, 20PPR) (installed)
(1) 3/16” spacer
(1) male/female adapter2
(1) Flat washer
(1) 10-32 screw3,4
Wiring
Refer to the following wiring diagrams for proper connection of DC Voltage, Armature, and Electrical
Wiring
Size all wires that carry line currents as specified by applicable national,
state, and/or local codes.
Separate control wires from AC lines when routed in conduit or wire trays.
caution!! turn poWer off While making Wiring connections.
improper installation or operation of this digital potentiometer may cause injury to personnel or equip-
ment failure. the device must be installed in accordance With local, state, and national safety codes.
make certain that the poWer supply is disconnected before attempting to service or remove any compo-
nents!!! ifthe poWer disconnect point is out of sight, lock it in disconnected position and tag it to pre-
vent unexpected application of poWer. only aqualified electrician or service personnel should perform
any electrical troubleshooting or maintenance. atno time should circuit continuity be checked by
shorting terminals With ascreWdriver or other metal device.

Page 10 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
P1 Terminal Block Wiring Diagrams
NOTE: Speed pickups shown above are not required for open-loop operation.
PICK-UP MOUNTED
TO MOTOR SHAFT
AC INPUT
AC INPUT
black
white
red
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
GSDA-DP-D
MASTER
2 AMP
HIGH OUTPUT
WIPER OUTPUT
COMMON
+5VDC
SIGNAL 1
(Mounts on rotating
end shaft with 10-32
tapped hole, 1/2" deep)
P1-9*
P1-10
P1-11
P1-12
}85-265VAC
}Form C
Relay output
(Programmable)
Alarm Output - Normally Open
Alarm Output - Common
Alarm Output - Normally Closed
* P1-9 signal input may be programmed for a number of functions,
including jog, inhibit, etc.
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
P1-10
P1-11
P1-12
* Optional Inhibit Switch
FOLLOWER PICK-UP
MOUNTED TO
MOTOR SHAFT
black
white
red
white
COMMON
+5VDC
SIGNAL 1
SIGNAL 2
SIGNAL 2
LOW OUTPUT }Connect to the speedpot
of the control being driven.
High must be positive
voltage with respect to low.
}Form C
Relay output
(Programmable)
Alarm Output - Normally Open
Alarm Output - Common
Alarm Output - Normally Closed
AC INPUT
AC INPUT
2 AMP
HIGH OUTPUT
WIPER OUTPUT
}85-265VAC
LOW OUTPUT }Connect to the speedpot
of the control being driven.
High must be positive
voltage with respect to low.
*
black
GSDA-DP-D
FOLLOWER
(Mounts on rotating
end shaft with 10-32
tapped hole, 1/2" deep)
GSDA-PU2x
GSDA-PU2x
Wiring Terminal Functions
• P1-1 (AC / N) – For single-phase AC systems with a grounded neutral, connect the neutral AC line to
this terminal. For systems with two hot AC lines, connect either of the hot AC lines to this terminal.
• P1-2 (AC / L) – For single-phase AC systems, connect the hot AC line to this terminal. For systems
with two hot AC lines, connect either of the hot AC lines to this terminal.
• P1-3 (HI) – This is the POT HI reference terminal. This terminal must be connected to the most
positive speed pot input terminal (minimum 2.5VDC) of the partner control device. This terminal will
generally be referred to as Pot HI or +V for positive supplies, and Com for negative supplies.
• P1-4 (WP) – This is the Wiper output terminal. This terminal will output an analog voltage signal
proportional to the referenced voltage signals connected to P1-3 (HI) and P1-5 (LO). This terminal
should be connected to the wiper or signal input of the partner control device.
• P1-5 (LO) – This is the POT LO reference terminal. This terminal must be connected to the most
negative speed pot input terminal of the partner drive. This terminal will generally be referred to as Pot
LO or Com for positive supplies and –V for negative supplies.
• P1-6 (COM) – This is the common point for the control logic. The speed sensor common lead as well
as any other equipment or source needing to reference the control common will be connected to this
terminal.
• P1-7 (+5V) – This is a self-contained +5VDC power supply capable of up to 50 mA. The speed sensor

Page 11IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
supply lead can be connected to this terminal for its power source.
• P1-8 (S1) – This is the signal input terminal for the motor’s digital pickup or encoder (closed-loop
only). This signal is internally pulled-up to +5VDC via a 2.2K ohm resistor.
• P1-9 (S2) – This input can be programmed to perform a number of advanced functions. In follower
mode, this input is the signal input terminal for the master’s digital pickup or encoder. In master modes
(rate and time), this input can be congured to function as an emergency stop, inhibit, or jog command.
This signal is internally pulled-up to +5VDC via a 2.2K ohm resistor.
• P1-10 (1NO) – This is the normally-open contact of the user assignable relay output.
• P1-11 (1C) – This is the common contact of the user assignable relay.
• P1-12 (1NC) – This is the normally-closed contact of the user assignable relay output.
Basic Operating Information
Initial Drive Adjustments
Regardless of whether the GSDA-DP-D is being used in a closed-loop or open-loop operation, it is
helpful to know how to set the typical initial adjustments on the drive being controlled.
IMPORTANT: If the drive that the GSDA-DP-D is controlling has a Max Speed or Gain setting, that will
interact with the setup. Therefore, it is best to start with the drive’s Max Speed or Gain control set to about
a 2/3 of its highest setting, as shown on the drawing below. If the Max Speed/Gain on the drive is set too
low, the GSDA-DP-D may not ever be able to attain the desired speed setting, and if it is set too high, it
may be difficult or impossible to achieve stability. In the worst case, the system may hunt or oscillate.
Also, if the drive has Current Limit settings, during P-I-D tuning (only), the Current Limit should, if at all
possible, be set such that the drive is not in Current Limit. Further, when in in closed-loop operation, the
drive should never require I.R. Comp, so set that control to minimum (and leave it there). Similarly, the
GSDA-DP-D has both Accel and Decel, so those drive settings should be set to minimum (and left there).
MIN MAX C.L. IR
ACEL DECL
Initial Trimmer Settings
Note: Set C.L. appropriately after P-I-D Tuning!
Closed-Loop Control Algorithm Discussion and P-I-D Tuning
If the unit is configured for closed-loop operation, a true P-I-D speed control algorithm is employed,
which allows precise and quick response to set speed or load changes. The three parameters, 26, 27 and
28 (Proportional, Integral, Derivative, respectively) are adjustable as shown in the software parameters
table. P-I-D can be tuned to get precise speed response and regulation.
When adjusting P-I-D, begin by using the factory defaults the control is preset to: P (Parameter 26) to
150, I (Parameter 27) to 20, D (Parameter 28) to 10. If further adjustment of P-I-D is needed, follow these
steps:
To adjust P: (Parameter 26): Run the motor from zero speed to the set speed. If the start up response of
the motor is too slow, increase P in increments of 20 until the desired start up response time is obtained. If
the start up response time is too fast, decrease P in increments of 10 until the desired response is reached.
P is used to adjust the start up response time only. The start up response time is approximately 0 to 60%
of the set speed. I can be used if adjustment of the upper response time (60 to 100% of the set speed) is
needed.
To adjust I: (Parameter 27): Run the motor from zero speed to the set speed. If the upper response
time (60 to 100% of the set speed) has any hesitation or has too slow of a response, then increase I in
increments of 5 until the hesitation is eliminated and/or the desired upper response time is obtained. If
the upper response time is too fast or has too much overshoot, decrease I in increments of 3 until the

Page 12 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
overshoot is eliminated and/or the desired upper response time is reached.
To adjust D: (Parameter 28): D can be used to dampen the effect of P. By making D too large, the
response time of the control can be reduced, so keep D as small as possible on non-regenerative controls.
Generally speaking, the proportion of P-I-D seems to be more critical than the individual values, i.e..
values of 50-50-50 will achieve virtually the same results as 999-999-999.
Closed-Loop Master (Rate & Time) and Follower (Ratio) Modes
GSDA-DP-D speed controls have two basic modes of operation, master and follower. In the master
modes, the controls are capable of operating independently; whereas, in the follower mode, the control
requires a signal from a master to operate. The follower mode is used in applications which require the
controller to closely follow a master process. For example, if a factory has ten conveyors which must
be synchronized over long periods of time, an industrial engineer could use one speed control unit as
a master control for the first conveyor and nine speed control units as slaves or followers which would
receive their speed commands from the first conveyor’s master control or pickup.
In Master Rate Mode, the speed control unit controls the rate of the motor by tracking the motor’s pickup
pulses which are applied to signal input 1 (S1). In this mode, the display indicates in rate units such as
gallons-per-minute, feet-per-second, or RPM.
In Master Time Mode, the speed control unit controls the process time by tracking the motor’s pickup
pulses which are applied to signal input 1 (S1). In this mode, the display indicates in time units such
as HH:MM or MM:SS, where HH is hours, MM is minutes, and SS is seconds. This mode is most
commonly used in time-sensitive processes such as conveyor ovens and plating applications.
In Follower Mode, the speed control unit tracks the rate of the pulses which are applied to the master
signal input (S2). From these pulses, it calculates the speed of the master process in RPMs. This rate
is then multiplied by the percentage which is displayed on the user interface. The display is in 0.1% of
master units. For example, 675 = 67.5 percent of master speed. A master running at 1350 RPM, would
cause the follower to run its motor at 67.5% * 1350 RPM or 911.25 RPM. Typical follower applications
include synchronized rotation, synchronized conveyors, and some web-material processes.
Open-Loop Control Algorithm Discussion and Setup
If the GSDA-DP-D is configured for open-loop operation, the P-I-D control method described above is
not used, nor is a speed pickup required. Instead, a control method is employed which is not based on
speed, but rather a percentage of maximum output voltage that will be developed across the LO and WP
terminals (P1-5 and P1-4, respectively), which in turn is used to control the attached drive. In open-loop
operation, the speed control unit operates as a Master Rate (in this case, % of max output) control only.
Setting the Operation Mode (Parameter 10) to Master Time or Follower modes will result in unpredictable
operation.
Setup consists of setting the Motor Control Method (Parameter 22) to a value of 32, plus the 4 Parameters
that define the scaling of the output voltage. Two of the Parameters, Display Min (Parameter 20) and
Display Max (Parameter 21) perform the same function as in closed-loop operation; that is, defining the
range of valid engineering units to which the speed control units can be set. The other two Parameters
Output Percent Min (Parameter 26) and Output Percent Max (Parameter 27) are used to define the
minimum and maximum output voltage percentages that will be scaled across the engineering units range
set by Display Min and Display Max, above. Parameters 26 and 27 represent values that define the Output
percentages to “tenths of a percent” accuracy. In other words, a setting of 1000 actually means 100.0
(percent). Care should be taken that value in Parameter 21 is greater than the value in Parameter 20, and
the value in Parameter 27 is greater than the value in Parameter 26.
Once the desired setup of the speed control unit is achieved, IR Comp and Current Limit settings on the
drive that is being controlled by the speed control unit should be adjusted according to the manufacturer’s
setup procedure and the requirements of the particular application.
Although not used to control the output of the speed control unit, A speed pickup (if available) can still
be connected to display Actual (Tach) Speed, and for Actual Speed Alarm Limits. Otherwise, those two
functions should not be used in open-loop operation.

Page 13IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
Front Panel Reference
Tach
Parm
ValuAuto
Alm1 Alm2Man Error
---
RIGHT-SET
Display Window
Up & Down Buttons
ENTER (Select) Button
LED Indicators
How to Change an Item’s Value
1) Hold down the Enter button until Item-Selection Mode is entered. The Item Annunciator will light.
2) Using the Up and Down buttons, select the desired Item number to view or edit.
3) Press the Enter button to change the value of the Item. The “Valu” Annunciator will light.
4) Using the Up and Down buttons, change the Item’s value as desired.
5) Press the Enter button to permanently save the changes (Returns to Parameter-Selection Mode).
6) Select Item Zero (“0”) and press the Enter button to return to Running Mode.
Operating the User Interface
Although the GSDA-DP-D speed control unit user interface is very versatile, it is also simple to setup and
operate. With just a few button presses, it allows the user to configure a number of adjustable Parameters.
The LED display has three basic operating modes: Running Mode, Parameter-Selection Mode, and Value
Mode. Parameter and Value modes also have specific visual indicators (LED Annunciators) that allow the
user to immediately determine the current state or mode of the user interface. Note: Parameter-Selection
Mode (and Value Mode) can only be entered if the Program Enable jumper is in the On position.
Running Mode is the default display of the unit when power is applied. The speed control unit will spend
the majority of its time in this mode. In Running Mode, the display shows the Target or Actual (Tach)
speed value in the user-defined engineering units format for rate, time, or (in Follower mode) percentage
of Master. The control will continuously attempt to drive the motor to the requested Target. In this display
mode, the Up and Down buttons increase or decrease the displayed target value until either the display
minimum or display maximum limit is reached. Depending on the alarm configuration, these buttons may
also serve as an alarm-silence or alarm-reset button. For example, displays for rate, time, and follower
operating modes could be 13.60, 45:30, and 1000, respectively.
Additionally, the speed control unit has an Auto/Manual Annunciator which displays a solid light if the
source of the Target Setting comes from the 4-20mA input (Auto), or a blinking light if the Target Setting
comes from the front panel Target setting (Manual).
Parameter-Selection Mode can be entered by simply pressing and holding the Enter button down for
about three seconds. Once in Parameter-Selection Mode, the Item Annunciator will illuminate. The
display will indicate the currently selected Item number for editing purposes. Pressing the Up or Down
button will increase or decrease the selected Item number on the display. Although the Parameter numbers
are in numerical order, some numbers are skipped. These numbers represent reserved Parameters that are
not yet implemented and are not displayed.
In addition, Parameter numbers above 999 are actually located on the ModularBus card(s) that are
installed in the host drive. The numbering scheme is the ModularBus slot number (100, 200 or 500) times
10, plus the Parameter number. Once the desired Parameter number is displayed, pressing the Enter button
will change the display to the Value Mode. So, for example, to view/edit Parameter 20 on a ModularBus
card in Slot 200, browse to Parameter number 2020 (200 X 10 + 20). When in Parameter-Selection Mode,
pressing the Enter button with Parameter 0 selected will cause the unit to return to Running Mode. See the
Software Parameters for a list of available Parameters.
Value Mode is used to modify the value of the selected Parameter. When in Value Mode, the Valu

Page 14 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
Annunciator will illuminate. Pressing the Up or Down button increases or decreases the selected
Parameter’s value. With only one exception, value changes take effect immediately. For example, when
adjusting P-I-D settings, the change in response can be observed live, which greatly facilitates the P-I-D
tuning process. Once the desired value is showing in the display window, pressing the Enter button
again will return to Parameter-Selection Mode and the new value will be saved in permanent memory.
Removing power from the unit while in Value Mode will result in the specified new value being lost, and
the previous (old) value being used. This can be used as an undo, for example, during editing a value that
is being edited in the wrong Item. Note: Changes to Parameter 10, Operating Mode, do not take effect
until power is removed and re-applied to the speed control unit.
Detailed Configuration Instructions
Default Configuration
When shipped from the factory, the following basic settings are in place:
• Closed-Loop Rate Mode Operation in RPM
• Decimal Point Display: None
• Display Range: 0 - 2400
• Speed Range: 0 - 2400 RPM
• Accel and Decel: 9999 RPM per second
• Signal Input 2 (S2) Mode: Jog (JOG1) @ 1000 RPM when Low
• Alarm 1 and Alarm 2 Outputs: Disabled
Resetting to Factory Defaults
The factory-default settings can be easily restored using either of two methods. Both methods require the
Program Enable jumper to be in the On position. The first is to apply power to the unit with both the Enter
and Down buttons pressed for 3 seconds. The second is to change the value of Parameter 95 to 5.
JP1 (Program Enable Jumper)
The JP1 jumper is located under the dust cover on the back end of the upper board. When the jumper
is set to the Off position, all programming features are locked out from the front panel user. When the
jumper is in the On position, the programming Parameters are open to change. JP1 is shipped from the
factory set in the On position.
Setting and Reading SoftSwitches
Like many other devices, the motor speed control has the ability to select between a number of yes/no or
on/off options, depending upon the application. Traditionally, this sort of option-selecting was done with
some sort of physical switch or switches (such as a DIP switch), or by other means, such as the jumper
block used to enable/disable programming on this unit. There are two problems with this approach to
option-selection:
• Both DIP switches and jumper blocks are physically large, and most require that the device be at least
partially disassembled to gain access to them.
• On a device with more than just a very few options, the number and combinations of switches quickly
becomes overwhelming.
Because of these drawbacks, this motor controller takes a different approach (where appropriate):
SoftSwitches.
It is easiest to think of a Parameter containing SoftSwitches as a DIP switch containing from one to
thirty-two switches. But instead of actually flipping a switch on or off, you can set and read these
switches as decimal numbers, each of which represents a binary switch number. Each switch, from #1
through #32, has been assigned a decimal number that represents its position in the virtual DIP switch
assembly. When that number is used, it means that the switch is on. For example, the decimal number that

Page 15IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
represents switch #4 is 8, the number that represents switch #6 is 32, and so on. See the table below for a
full explanation of these values.
Note: Due to display limitations, switches 15 through 32 are currently unused.
Switch # Decimal Number
Representing Binary
Value For Switch
Switch # Decimal Number
Representing Binary
Value For Switch
1 1 8 128
2 2 9 256
3 4 10 512
4 8 11 1024
5 16 12 2048
6 32 13 4096
7 64 - -
So, the decimal number contained in a SoftSwitch Parameter is nothing more than the sum of the numbers
representing the on switches. For example, if you wanted to set switches #1, #4, and #7 to the on position,
you would place the number 73 (1 + 8 + 64) into the Parameter containing those SoftSwitches; if you
wanted to set switches #5 and #6 on, you would place the number 48 (16 + 32) into the Parameter, and so
forth. Simply add-up the decimal values of the switches you wish to turn on, and place the total, or sum,
into the Parameter containing the SoftSwitches.
The settings of the SoftSwitches can also be read the same way: For example, if a Parameter containing
the SoftSwitches has been set to the number 11, you can tell that switches #1, #2 and #4 are on. You can
tell this by subtracting the decimal values, from highest to lowest, starting at the highest value that is
less than or equal to the total. Keep subtracting, but if you get a negative number as a result, then don’t
subtract that decimal value (add it back in before proceeding). Work your way downward in this manner
toward Switch #1, but when your total reaches zero, you are finished.
Try a few examples of your own, and very soon you will be easily setting and reading SoftSwitches.
Setting and Reading Alarm Conditions
Taking advantage of the SoftSwitches feature described above, the motor speed control is equipped with
two alarm outputs, which can be independently set to activate on any of 16,384 possible combinations
of conditions or events that could be occuring at any one time. See the following table for a list of these
condition flags.
The conditions are logically OR-ed together to form the particular alarm output. If the SoftSwitches for
the Tach Outside Limits and the Pickup Stalled conditions for Alarm1 are set to On, then Alarm1 will
be true when either one or both of those conditions are true. However, for even more flexibility, each
condition can be combined in a logical AND fashion to override the alarm output.
Additionally, each condition can be inverted before being sent to the AND function, for even greater
flexibility. Please note that if a particular condition is inverted, the corresponding switch in the
appropriate AND Item (52/72) is inverted as well.
Also, setting any of the Softswitch Parameters in the OR/Invert/AND Alarm Conditions (Parameters
50-52 and 70-72) to a value of zero effectively removes the effect of their logic from the circuit.
Therefore, even though the Alarm logic conditions are cascaded OR -> Invert -> AND, if, for example,
the application does not need any AND conditions, simply set the value of the AND Item (52 and/or 72)
to zero, and the AND function will be jumped around. In that case, however, it would also be best to set
the Inverter Parameter (51 and/or 71) to zero as well.

Page 16 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
Table 1: BCD Values for Drive Condition Flags
BCD Value Description
0No flags are currently active
1Accel/Decel ramp in progress
2S1 (Main) Actual Speed (Tach) is outside alarm limits
4Target Speed is outside alarm limits
8Target Speed = 0
16 S1 (Main) Pickup is stalled
32 S2 (Leader) Pickup is stopped (valid only in Follower Mode)
64 Jog function is activated
128 Inhibit function is activated
256 E-Stop function is activated
512 Drive is at maximum output
1024 Run condition
2048 Reserved
4096 Reserved
Table 2: BCD Values for Drive Condition Flags
BCD Value Description
0No flags are currently active
1Slot 100 Alarm1 activated (valid only if ModularBus card installed
in this slot)
2Slot 200 Alarm1 activated (valid only if ModularBus card installed
in this slot)
4Slot 500 Alarm1 activated (valid only if ModularBus card installed
in this slot)
8Maintenance timer
16 Reserved
32 Reserved
64 Reserved
128 Reserved
256 Reserved
512 Reserved
1024 Reserved
2048 Reserved
4096 Reserved
Alarm Output Routing
The output of Alarm1 is permanently routed to control the Form-C Relay output on the motor speed
control itself (see Hook-up Diagram, P1-9 through P1-11). The output of Alarm2, however, can be routed
(through the use of Parameter 81) to control a relay located in any one of the three ModularBus slots 100,
200 or 500.

Page 17IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
Alarm Logic
Note: The circuitry shown in the following logic drawing is actually implemented in software, not
hardware, and although it makes little difference to the final output produced, that fact should be kept in
mind.
Also note that the switches on the outputs of the OR gate, the AND gate, and the implied AND gate are
only under indirect user control. That is, they are set automatically by the action of other settings that
are under user control. For example, the switch on the output of the OR gate is automatically set to the
uppermost position (as shown on the following logic drawing) when Parameter 50 (or 70 for Alarm2) is
set to zero.
Often there is more than one way to connect the signals and logic to achieve the desired result. But
determining the proper signal polarity to use is often a tricky problem in logic circuits. Sometimes it takes
a bit of careful planning to arrange inverted and non-inverted signals properly. Also, keep in mind that
standard logic tricks, such as the use of negative logic techniques, can be used to further expand your
options. See the Application Example later in this manual for further details.

Page 18 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
Alarm Logic Application Example
[1] Accel/Decel Ramp
[2] Actual Speed Outside Limits
[4] Target Speed Outside Limits
[8] Target Speed = 0
[16] (Main) Pickup Stalled
[32] (Leader) Stopped
[64] Jog
[128] Inhibit
[256] E-Stop
[512] Maximum Output
[1024] Run
[2048] Reserved
[4096] Reserved
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Drive Condition Flags
[BCD Values]
Parameter 50
(70)
Parameter
51
(71)
Parameter
52
(72)
Parameters
51,52, 66, 67 = 0
(71,72, 86, 87 = 0)
AND
Alarm1
(Alarm2)
Note:
Numbers in parentheses refer to Alarm2
OR
“Implied”
AND
Parameter
50, 65 = 0
(70, 85 = 0)
“Open” When Parameters
50, 51, 52, 65, 66, 67= 0
(70, 71, 72, 85, 86, 87= 0)
Parameter
50, 65 = 0
(70, 85 = 0)
Parameters
51,52, 66, 67 = 0
(71,72, 86, 87 = 0)
[1] Slot 100 Alarm1
[2] Slot 200 Alarm1
[4] Slot 500 Alarm1
[8] Maintenance Timer
[16] Reserved
[32] Reserved
[64] Reserved
[128] Reserved
[256] Reserved
[512] Reserved
[1024] Reserved
[2048] Reserved
[4096] Reserved
Parameter 65
(85)
Parameter
66
(86)
Parameter
67
(87)
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Page 19IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
GSDA-DP-D Software Parameters
Parameter Description Value Range Units Default
0Select parameter 0 to return to
Run mode n/a – n/a
Read-Only Parameters
1 Model Number 46 = GSDA-DP-D 46
2 Software Build 1-9999 n/a
3 Hardware Version 1-9999 n/a
4 Network Version (Reserved) 1-9999 n/a
5 Serial Number - Major (Reserved) 0-9999 n/a
6 Serial Number - Minor (Reserved) 0-9999 n/a
8 Drive Condition Flags (See "Flags" - Table #1 Below) BCD n/a
9 Drive Condition Flags (See "Flags" - Table #2 Below) BCD n/a
General Setup Parameters
10 Operating Mode
1 = Rate Mode
2 = Time Mode
3 = Follower Mode
1
11 Display Brightness" 0-31 - (Dim-Bright) 26
12 Display Mode
1 = Target Speed
2 = S1 Actual Speed
3 = S2 (Leader) Speed
1
13 Decimal Point Position
0 = Disabled - (XXXX)
1 = X.XXX
2 = XX.XX
3 = XXX.X
4 = XXXX
0
14 Keypad Mode 1 = Linear - Constant Rate
2 = Non-Linear - Accelerating Rate 2
15 Keypad Scroll Delay 0-30 - (Fast-Slow) 10
16 Power-Up Target Speed
1 = Force Zero Speed
2 = Force Power-up Value
3 = Use Previous Target Speed
3
17 Power-Up Value 0-9999 (Eng. units) 0
18 Front-Panel Double-Click
Destination
0 = Double-Click Ignored
1 = Inhibit
2 = Estop
3 = Jog1
4 = Jog2
5 = Auto/Man 4-20 mA Card
0
19 Reserved n/a 0
Display and Control/PID Setup Parameters
20 Display Minimum 0-9998 (Eng. units) 0
21 Display Maximum 1-9999 (Eng. units) 2400
22 Motor Control Method
0 = Gain Tracking Off, Low Spd
Mode Off
1 = Gain Tracking On, Low Spd
Mode Off
2 = Gain Tracking Off, Low Spd
Mode On
3 = Gain Tracking On, Low Spd
Mode On
4 through 31 - DO NOT USE!
32 = “Open Loop” Operation
1
23 Accel Setting 1-9999 (Eng. units) 9999
24 Decel Setting 1-9999 (Eng. units) 9999
26 Proportional Gain 0-9999 150
27 Proportional Gain 0-9999 20
28 Derivative Gain 0-9999 10
29 Startup Lag Compensation 0-5000 0
Signal Input #1 (S1) Setup Parameters
30 S1 Display Reference 1-9999 (Eng. Units) 2400
31 S1 Reference RPM 1-9999 RPM 2400

Page 20 IronHorse GSDA-DP-D DC Drives Accessory User Manual – 1st Ed. Rev. A – 11/11/2019
Parameter Description Value Range Units Default
32 S1 Pulses Per Revolution 1-9999 PPR 20
33 S1 Initial Stall Timeout 0, 5-9999 - (0 = Defeat) Sec. 0
34 Signal Input (S1) Running Stall
Timeout 0-9999 - (0 = Defeat) 0.10 Sec. 0
Signal Input #2 (S2) Setup Parameters
35 S2 Input Configuration
1 = Disabled - (Follower Mode)
2 = E-Stop - S2 High
3 = E-Stop - S2 Low
4 = Inhibit - S2 High
5 = Inhibit - S2 Low
6 = Jog - S2 High
7 = Jog - S2 Low
7
36 S2 Setpoint
Setpoint for Jog1 Function 1-9999 (Eng. Units) 1000
37 S2 Pulses Per Revolution -
(Follower Only) 1-9999 PPR 20
38 S2 Stopped Timeout - (Follower
Mode Only) 0-9999 - (0 = Defeat) 0.10 Sec. 0
39 Disable S2 In Manual Mode 0 = Disabled
1 = Enabled 0
User Input #1 (UIN1) Setup Parameters
40 UIN1 Input Configuration 1 = Disabled 1
41 Setpoint for Jog2 Function 1-9999 (Eng. Units) 1000
42 Inhibit Configuration
0 = No Accel/Decel
1 = Decel Only, No Accel
2 = Accel Only, No Decel
3 = Accel & Decel
0
Alarm Output #1 Setup Parameters
50 Alarm1 Logical "OR" Activation
Conditions (See "Flags" - Table 1 Below) BCD 0
51 Alarm1 Logical Inverters (See "Flags" - Table 1 Below) BCD 0
52 Alarm1 Logical "AND" Activation
Conditions (See "Flags" - Table 1 Below) BCD 0
53 Alarm1 Output Style & Reset
Mode
1 = Constant & Auto Reset
2 = Constant & Manual Reset
3 = Pulsed & Auto Reset
4 = Pulsed & Manual Reset
1
54 Alarm1 Reset Configuration
1 = No Silencing - Reset on Enter
Button
2 = No Silencing - Reset on S2 High
3 = No Silencing - Reset on S2 Low
4 = Silencing - Reset on Enter
Button
5 = Silencing - Reset on S2 High
6 = Silencing - Reset on S2 Low
1
55 Annunciator Alm1 Flash On Active
Alarm1
0 = No Annunicator Flash
1 = Annunicator Flash 0
56 Alarm1 Output Pulse ON Time 1-3600 Secs. 1
57 Alarm1 Output Pulse OFF Time 1-3600 Secs. 1
58 Alarm1 Output Pulse Count 0-9999 0
59 Alarm1 Lower Limit 0-9999 (Eng. Units) 0
60 Alarm 1 Upper Limit 0-9999 (Eng. Units) 9999
65 Alarm1 Logical "OR" Activation
Conditions (See "Flags" - Table 2 Below) BCD 0
66 Alarm1 Logical Inverters (See "Flags" - Table 2 Below) BCD 0
67 Alarm1 Logical "AND" Activation
Conditions (See "Flags" - Table 2 Below) BCD 0
Alarm Output #2 Setup Parameters
70 Alarm2 Logical "OR" Activation
Conditions (See "Flags" - Table 1 Below) BCD 0
71 Alarm2 Logical Inverters (See "Flags" - Table 1 Below) BCD 0