Automationdirect.com IRONHORSE GSD1 Series User manual

Page 1
IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
™
GSD1 SerieS DC DriveS USer ManUal
User ManUal nUMber: GsD1-48_UMP
NOTE: (table)

Page 2 IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
~ WarninG ~
Thank you for purchasing automation equipment from Automationdirect.com®, doing business as
AutomationDirect. 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©2015, 2018 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.

Page 3
IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
ConTenTS
WARNING � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Trademarks� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
GSD1 DC Drives User Manual Overview � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
IronHorse GSD1 Series DC Drives General Information � � � � � � � � � � � � � � � � � � � � � � � � � 4
Selection and Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
Dimensions� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
Installation and Wiring � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Operational Description: 0 to 10 VDC Analog Reference Signal to GSD1 � � � � � � � � � � � � � � 10
Trim Pot Adjustments � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11
Troubleshooting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11
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. 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 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
bytelePhOne: 770-844-4200 (MOn.–fri., 9:00 a.M.–6:00 P.M. e.t.)
Onthe 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
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 AWARNING. thIs INfoRmAtIoN could pReveNt INjuRy, loss of pRopeRty, oR eveN deAth (IN extReme
cAses).

Page 4 IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
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 model (GSD1-48-10N4X) is 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.

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IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
SeleCTion anD SpeCifiCaTionS
GSD1 Series DC Drives
12VDC @ 10A 1/50 – 1/8 hp motor
24VDC @ 10A 1/50 – 1/4 hp motor
36VDC @ 10A 1/50 – 3/8 hp motor
48VDC @ 10A 1/50 – 1/2 hp motor
12VDC @ 20A 1/50 – 1/4 hp motor
24VDC @ 20A 1/50 – 1/2 hp motor
36VDC @ 20A 1/50 – 3/4 hp motor
48VDC @ 20A 1/50 – 1 hp motor
GSD1 Series DC Drives – Selection & Specifications
Model GSD1-48-10C GSD1-48-10N4X GSD1-48-20C
Package Configuration open frame NEMA 4X open frame
Power Quality Form Factor 1�05
Input Voltage ** 12/24/36/48 VDC ±15% (jumper selectable)
Output Voltage 0–12/24/36/48 VDC
Motor Rating (hp) 1/50 – 1/2 1/50 – 1
Output Current (continuous) 10A (DC) 20A (DC)
Current Overload Capacity 200% for 10s; 150% for 60s
Current Limit adjustable to 200% of motor Full Load Current, up to 200% of control current rating
Speed Adjustment *** 5kΩ potentiometer or 0–10VDC*** input signal
Speed Range 30:1
Speed Regulation 1% of base speed via adjustable IR compensation trim pot
Maximum Speed adjustable from 50% to 100% of base speed
Minimum Speed 0–30% of adjustable maximum speed
Acceleration adjustable from 0–10s
Deceleration 0�5s (non-adjustable)
Dynamic Braking no
Plugging Capability **** no
Internal Operating Frequency 18kHz
Power Connections (P1) Euro-style terminal block (14–28 AWG) Euro-style terminal block (10–14 AWG)
Signal Connections (P2) Euro-style terminal block (14–28 AWG)
External Fusing Required DC-rated @ 150% motor Full Load Current (up to 150% Continuous Output Current rating of drive)
Operating Temperature -30 to 65°C [-22 to 140°F] for Chassis
-15 to 60°C [5 to 140°F] for Enclosed
Thermal Protection none
Mounting Orientation Can be mounted in any orientation
Corrosive Gases NOT compatible with any corrosive gases
Package Configuration Black anodized aluminum extrusion
Weight 8oz [227g] 40oz [1049g] 8oz [227g]
Agency Approvals RoHS
Optional Accessories *
Replacement Potentiometer GSDA-5K
Digital Potentiometer GSDA-DP
* For accessories details, refer to the "GSD Series DC Drives Accessories" section at automationdirect.com.
** Input power supply must not exceed recommended voltage, or it may damage the GSD1 drive.
Linear power supply can be sized per drive voltage and motor full load current.
Switched power supply should be sized per drive voltage and double the motor full load current.
*** For 0–10 VDC input signal, please refer to “Operational Description: 0 to 10 VDC Analog Reference Signal to GSD1” on
page 10”
**** Plugging is a method of rapidly changing motor direction by reversing motor armature polarity, while the motor is still
running.

Page 6 IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
DiMenSionS
inches [mm]
GsD1-48-10c anD GsD1-48-20c
A
Model A
GSD1-48-10C 1�70 [43�1]
GSD1-48-20C 1�92 [48�7]
GsD1-48-10n4X

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IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
inSTallaTion anD WirinG
Install open-frame drives in an enclosure with a volume at least three times the volume of the open-
frame drive.
Do not mount controller where ambient temperature is outside the range of -10 to 45 °C (14–13 °F).
ImpRopeR INstAllAtIoN oR opeRAtIoN of thIs dc dRIve mAy cAuse INjuRy to peRsoNNel oR dRIve fAIluRe. the dRIve
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 compoNeNts!!! Ifthe poWeR dIscoNNect poINt Is out of
sIGht, lock It IN dIscoNNected posItIoN ANd tAG It to pReveNt 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.
befoRe AttemptING to WIRe the dc dRIve, mAke suRe All poWeR Is dIscoNNected. Recheck code desIGNAtIoN to
AssuRe pRopeR voltAGe Is pReseNt foR the dc dRIve. cAutIoN should be used IN selectING pRopeR WIRe sIze foR
cuRReNt ANd voltAGe dRop; mINImum WIRe sIze 14AWG foR 10 Amp models ANd 12AWG foR 20 Amp models.
doNot ReveRse posItIve ANd NeGAtIve bAtteRy / poWeR leAds, As thIs WIll dAmAGe the dc dRIve.
tochANGe motoR dIRectIoN, INteRchANGe the posItIve ANd NeGAtIve motoR ARmAtuRe leAds.
cAutIoN!! tuRN poWeR off WhIle mAkING WIRING coNNectIoNs.
cAutIoN!! set the voltAGe selectIoN jumpeR to mAtch the supply voltAGe. ANINcoRRect jumpeR settING WIll Not
cAuse dAmAGe to the dRIve, but WIll Affect oveRAll speed, mAxImum speed ANd IR compeNsAtIoN AdjustmeNts.
fUsinG
Externally fuse the +Battery input line with Littlefuse 314 series or Bussman ABC series or equivalent
fuses designed for use with motors and motor control systems; rated for the lesser of:
1) 200% of the continuous current rating of the drive, or 2) 150% of the motor full-load current.
(Fast-blow fuses are NOT recommended.) (AutomationDirect sells ABC series fuses.)
cUrrent liMit settinG anD cUrrent liMit (triP) OUtPUt
48V 36V 24V 12V
Voltage
Selector
Jumpers
Current Limit
Trip Output LED
Current Limit
Trip Output
Please note the following recommendations
regarding the Current Limit (Trip) Output and Setting:
• The Current Limit Output can be used to inhibit the
drive or break the power connection to the drive�
• The Current Limit Output threshold is the same as
the Current Limit Setting�
• To properly adjust the CURRENT LIMIT Setting, a DC ammeter should be placed in series with the
armature line� This meter can be removed after the DC Drive is adjusted�
• The Current Limit Output is immediate, without time delay, and is NOT retentive�
• Use with 12VDC relay� In order to maintain a current limit fault, use a latching relay�
• Source voltage from terminal P2-1�
• Current Limit Trip Output sinks to terminal P2-4 (50VDC@0�3A)�
• Recommended use with Inhibit, terminals P2-4 and P2-5�
• If you connect the current limit relay to the Pot HI (P2-1), supply voltage will be 10V, regardless of the
supply voltage to the drive� If the relay is connected to the supply voltage, the relay voltage needs to
match the supply voltage� The Current Limit Output is capable of up to 100V�
terMinal blOcks GSD1 Wiring Terminals
Type Wire Range* Tightening Torque
Barrier terminal block (P1) (Power) 14 – 28 AWG (10A) 7�0 lb·in [8�0 kg·cm]
10 – 14 AWG (20A) 8�5 lb·in [9�8 kg·cm]
Barrier terminal block (P2) 14 – 28 AWG 7�0 lb·in [8�0 kg·cm]
*Wire range of the terminal. See Installation and Wiring above for minimum wire sizes.

Page 8 IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
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 10.”
GsD1-48-XXc basic wirinG DiaGraM
P1
P2
(P1-4)
(P1-3)
(P1-2)
(P1-1)
5KΩ
Speedpot
White
Red
Orange
+
-
DC Power
Source
Motor
Customer
supplied
SPST switch
or relay
(P2-5)
(P2-4)
(P2-3)
(P2-2)
(P2-1)
Fuse
Accel
Max Speed
Min Speed
Current Limit
IR Comp.
IN4001 thru 4007
12V Relay Coil
*The suggested female wire connector for
the Current Limit Trip Output 0.110 in male
spade terminal is Molex Inc. P/N 1090030024
Voltage
Selector
Jumper
*Current
Limit Trip
Output
48V
36V
24V
12V
+
-
** Inhibit Circuit (P2-4 to P2-5): 7–10 VDC @ 0.2–1 mA;
Refer to “Control Inhibit Wiring Diagrams” for Control Inhibit wiring details.
Optional
Inhibit**
GSD1 Series Terminals
Terminal
Number Description Terminal Marking
P1-1 – Battery (–B)
P1-2 + Battery (+B)
P1-3 + Armature (+A)
P1-4 – Armature (–A)
P2-1 Potentiometer High (HI)
P2-2 Potentiometer
Wiper (WP)
P2-3 Potentiometer Low (LO)
P2-4 Common (COM)
P2-5 Inhibit (INH)
GsD1-48-10n4X basic wirinG DiaGraM
+
-
+
-
DC Power
Source
Motor
RED
RED
RED
ORANGE
Fuse
Gnd
WHITE
RED
RED
P1-1 P1-2 P1-3 P1-4 P2-1 P2-2 P2-3 P2-4 P2-5
Voltage
Selector
(see detail)
Optional
Inhibit*
* Inhibit Circuit (P2-4 to P2-5):
7–10 VDC @ 0.2–1 mA
Refer to “Control Inhibit Wiring Diagrams”
for Control Inhibit wiring details.

Page 9
IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
reversinG wirinG DiaGraMs
cAutIoN: WheN ReveRsING AspINNING peRmANeNt mAGNet dc motoR, cAutIoN must be tAkeN thAt the
ResultING cuRReNt thRouGh the ARmAtuRe of the motoR does Not exceed the oveRloAd RAtINGs of the dc
dRIve, oR the demAGNetIze RAtING of the motoR beING ReveRsed.
cAutIoN: eNsuRe thAt motoR RotAtIoN hAs stopped befoRe ReveRsING the ApplIed voltAGe.
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 10.”
GsD1-48-XXc reversinG wirinG DiaGraM
P1
P2
-1
-2
-3
-4
-1
-2
-3
-4
-5
Red
Orange
+
-
Customer
supplied
SPST switch
or relay
Fuse
Accel
Max Speed
Min Speed
Current Limit
IR Comp.
IN4001 thru 4007
12V Relay Coil
Motor
Customer supplied
3PDT Center-off
Center-blocked switch
White
** Select battery / power voltage
as required per application
and model specifications.
DC Power
Supply**
12/24/36/48
VDC**
+
-
* Inhibit Circuit (P2-4 to P2-5): 7–10 VDC @ 0.2–1 mA
Refer to “Control Inhibit Wiring Diagrams” for Control Inhibit wiring details.
Voltage
Selector
Optional
Inhibit *
Current
Limit Trip
Output Inhibit*(P2-5)
Common*(P2-4)
Pot Low (P2-3)
Pot Wiper (P2-2)
Pot High (P2-1)
5kΩ
Speedpot
-Arm (P1-4)
+Arm (P1-3)
+Battery (P1-2)
-Battery (P1-1)
cOntrOl inhibit wirinG DiaGraMs
Always use a shielded cable when connecting to the inhibit terminal. The shield of the cable
should connect to the Common terminal of the DC Drive.
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 10.”
GsD1-48-XXc cOntrOl inhibit wirinG DiaGraMs
Inhibit (P2-5)
Common (P2-4)
Pot Low (P2-3)
Pot Wiper (P2-2)
Pot High (P2-1)
5k Ω
Speedpot
Orange
Red
White
SPST Switch
open = stop
close = run
P2**
Inhibit* (P2-5)
Common* (P2-4)
Pot Low (P2-3)
Pot Wiper (P2-2)
Pot High (P2-1)
P2**
SPST Switch
open = run
close = stop
Inhibit via speedpot
provides starting and stopping through accel parameters
Using inhibit input
provides fast start-stop by bypassing accel circuit
** Use shielded cable when connecting to the Inhibit terminal. Connect the cable shield to the Common terminal of P2.
* Inhibit Circuit (P2-4 to P2-5): 7–10 VDC @ 0.2–1 mA

Page 10 IronHorse GSD1 DC Drives User Manual – 2nd Edition, Revision B – 10/12/2018
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.