PEGASUS TECHNOLOGY GRAMEYER GCDT-02 Specification sheet

MPEN09985
FIELD APPLICATION RELAY
GCDT-02
GCDT-02
OPERATION AND INSTALLATION MANUAL
Revision 05 of 2019-09-23
PEGASUS TECHNOLOGY EQUI. ELETR. LTDA
PEGASUS TECHNOLOGY EQUI. ELETR. LTDA
St. Mal. Castelo Branco, 5203 – Schroeder – SC – Brazil 89275-000
e-mail: [e-mail] - www.pegasustech.com.br
Phone: [phone]

GCDT-02 Rev. 05 of 2019-09-23
© 2018 PEGASUS TECHNOLOGY Equipamentos Eletrônicos LTDA.
All right reserved.
This manual may in no way be reproduced, filed or transmitted through any type of media,
whether it be electronically, by printing, phonographically or any other audiovisual means without prior
consent from PEGASUS. Infringement is subject to prosecution under the law.
Due to the continuous improvement of PEGASUS products, the present manual may be modified
and/or updated without prior notice which may result in new revisions of the installation and maintenance
manuals for the same product. PEGASUS reserves itself the right not to update automatically the
information included in this manual. However, customers may at any time request any updated version of
the manual, which will be supplied to them free of charge.
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GCDT-02 Rev. 05 of 2019-09-23
* If requested, PEGASUS can supply an extra copy of this manual. The equipment serial number and model should
be informed by the customer, when making the request.
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GCDT-02 Rev. 05 of 2019-09-23
Safety Information
To guarantee the safety of the operators, the correct installation and proper operation of the
equipment, the following precautions must be taken.
●Installation and maintenance services should be performed only by qualified personnel, using
appropriate equipment;
●The product instruction manual and specific product documentation must always be consulted
before proceeding with its installation, handling and parameter setting;
●Adequate precautions should be taken to avoid drops, knocks and/or risks to the equipment;
Do not touch the input and output connectors and keep them isolated from the rest of the
principal command circuit of the generator.
Always disconnect the main power supply and wait for a complete stop of the machine
before touching any electrical component associated with the equipment including the
control connectors, since high voltages may be present even after the power has been
switched off.
The equipment’s electronic boards can have components that are sensitive to
electrostatic discharges. Do not directly touch components or connections. If this is
absolutely necessary, then first touch the grounded metal body or use the proper ground
bracelet.
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GCDT-02 Rev. 05 of 2019-09-23
Storage Information
Should it be necessary to store the equipment, as well as any of its parts, i.e., electronic boards,
panels, electronic components, spare parts, etc..., for a short period of time prior to their installation
and/or placing them in operating condition, the following precautions should be observed:
●The equipment and its parts must be kept in their original packaging or in packaging which
provides the same safety conditions concerning physical damage, high temperatures and
humidity, to prevent oxidation of the contacts and metal parts, damage to integrated circuits or
any other damage due to improper storing;
●The properly packaged equipment must be stored in a dry, well ventilated place away from
direct sunlight, rain, wind and other adverse weather conditions, to guarantee the preservation of
its operational characteristics;
The non-observance of the above recommendations, could exempt the company
supplying the equipment from any responsibility referring to the resulting damages as
well as the loss of warranty of the equipment or of the damaged part.
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GCDT-02 Rev. 05 of 2019-09-23
Index
1 - General Information......................................................................................................................7
1.1 - Introduction.........................................................................................................................7
1.2 - General Characteristics.........................................................................................................7
1.3 - Electrical Characteristics........................................................................................................8
1.4 - Mechanical Characteristics.....................................................................................................8
1.5 - Connection Diagram.............................................................................................................9
1.6 - Principle of Operation..........................................................................................................10
1.7 - Slipping Frequency Adjustment............................................................................................11
1.8 - LED Indicators....................................................................................................................13
2 - Equipment Test Procedure...........................................................................................................14
2.1 - Test Procedure....................................................................................................................15
2.1.1 - Assembly Preparation..................................................................................................15
2.1.2 - Field Application Test..................................................................................................15
2.1.3 - Crowbar Disabling Test...............................................................................................15
2.1.4 - Field Application Test With the Rotor Synchronized........................................................16
2.1.5 - Test for Firing Interruption in Case of Voltage Drop.......................................................16
2.1.6 - Test for Crowbar Passive Firing.....................................................................................16
3 - Wire connections to the Connector...............................................................................................17
3.1 - Bracket for Wire Support.....................................................................................................18
3.2 - Mechanical Assembly...........................................................................................................19
4 - Dimensions (mm)........................................................................................................................20
5 - Problems, Causes and Solutions....................................................................................................21
Figure Index
Figure 1.1 - GCDT-02 Connection Diagram...........................................................................................9
Figure 1.2 - Wave Forms in Field Application.......................................................................................11
Figure 1.3 - Detail of the Slipping Adjustment “Dip Switch”...................................................................11
Figure 1.4 - GCDT-02 LED's...............................................................................................................13
Figure 2.1 - Test Circuit.....................................................................................................................14
Figure 3.1 - Cables Connection..........................................................................................................17
Figure 3.2 - Cables Connection..........................................................................................................17
Figure 3.3 - Wire Connections and Bracket Dimensional (mm)..............................................................18
Figure 4.1 - Dimensional Drawing......................................................................................................20
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1 -
1 -G GENERAL ENERAL I INFORMATION NFORMATION
1.1 - Introduction
The GCDT-02 relay is used for controlling synchronism of synchronous motors, controlling
the application of excitation current to the field based on the rotor slip frequency and the polar
angle.
This relay system permits the application of excitation voltage on the exciter field from
motor start-up, without worrying about the best moment to apply excitation to the rotor, since
the system executes this function automatically, synchronizing the motor when it reaches
adequate speed and the polarity of the rotor is perfectly aligned with the stator. In addition, the
GCDT-02 performs a crowbar function, placing the start-up resistor in parallel with the field
during the start-up process and afterwards, if so required, in the event of a voltage transient on
the field.
1.2 - General Characteristics
•Compact and resin encapsulated, the GCDT-02 can be installed on the rotor of a
brushless motor in any position or orientation;
•Powered directly by excitation voltage (DC);
•Withstands a wide supply voltage variation;
•Performs the following functions:
•Connects the discharge resistor on motor start-up;
•Connects excitation to the field at the optimal time (speed and alignment) ;
•Protection against field overvoltage after start-up, by connecting the discharge
resistor;
•The crowbar thyristor blocks whenever .7this thyristor closes (becomes
conductive)during normal motor operation (after start-up).
•The firing of the thyristors is done by DC application, controlled, assuring high reliability
and robustness.
•The adjustment of the setpoint for frequency slip for field connection is performed by a
Dip Switch, assuring precision and fine adjustment of the reference setpoint in the field,
and it is not necessary to use the function generator for adjustment;
•Status indicator LEDs for: Power supply OK (PWR OK), principal thyristor triggered (TRIG
PR), Crowbar thyristor conducting (CR ON), crowbar thyristor triggered (TRIG CR), and
crowbar disconnection thyristor triggered (CR OFF);
•All units are individually tested and leave the factory with a copy of the test results;
•All units leave the factory properly weighed and with its value duly registered on the test
results to allow for rotor balancing in case of need to replace the module;
•It can be used for thyristor firing (mounted on motor rotor) or for DC contactor closure
(panel mounted).
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1.3 - Electrical Characteristics
•Maximum power supply voltage: 900 Vdc;
•Minimum power supply voltage: 30 Vdc;
•Crowbar firing voltage: 520 V (standard value), allowing for modifications according to the
application requirements;
•Maximum voltage induced in the discharge resistor during start-up: 1000 Vpeak;
•Minimum recommended voltage induced in the discharge resistor during start-up: 50 Vpeak;
•Sensitivity of the rotation sensor: +/- 5 V;
•Thyristors firing current: 0,5A constant;
•Thyristors firing maximum voltage: 7V;
•Maximum power consumed: 15W;
•Slipping frequency adjustment range: 0,49 to 5 Hz (standard value), allowing for
modifications to satisfy the application requirements;
1.4 - Mechanical Characteristics
•Locking quick connect electrical terminals and spring loaded electrical contacts, assure a
rugged construction and reliability for operation in vibrating environments avoiding the
possibility of slackening of the connection. It also allows for easy maintenance or
replacement on the field;
•Metallic box with high mechanical strength to avoid deformations due to the action of
centrifugal force;
•Polyurethane resin encapsulated;
•Equipment dimensions: (see item 5);
•Maximum ambient temperature: GCDT-02 (60 ºC) and GCDT-02E (80 ºC);
•The electrical drawings and connections as well as a table for slippage frequency adjustment
is printed onto the box to allow for easy installation, maintenance and adjustment of the
GCDT-02;
•Diameter of the electrical connection cables: 1,5 to 2,5 mm².
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GCDT-02 Rev. 05 of 2019-09-23
1.5 - Connection Diagram
The figure 1.1 shows the connection diagram of the GCDT-02. The wires used for
connections must have a minimum diameter of 1,5 mm² and 2,5 mm² maximum.
LEGEND:
•TR_PR_A: Main thyristor. Connection to the thyristor anode;
•TR_PR_G: Main thyristor. Connection to the thyristor gate;
•TR_CR_A: Crowbar thyristor. Connection to the thyristor anode;
•TR_CR_G: Crowbar thyristor. Connection to the thyristor gate;
•TR_AX_A: Auxiliary thyristor. Connection to the thyristor anode;
•TR_AX_G: Auxiliary thyristor. Connection to the thyristor gate;
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FIGURE IGURE 1.1 1.1 - GCDT-02 C - GCDT-02 CONNECTION ONNECTION D DIAGRAM IAGRAM

GCDT-02 Rev. 05 of 2019-09-23
1.6 - Principle of Operation
When the synchronous motor is started, an induced voltage is originated at the field
terminals, with frequency equal to the armature frequency and amplitude depending on the
type of start resistor utilized.
At this moment, the field application relay commands the firing of the crowbar thyristor
(TR_CR) through voltage, that is, when the voltage induced at the field (positive) exceeds the
firing voltage value of the crowbar (the relay parameter normally adjusted to 520V), the
crowbar thyristor (TR_CR) is fired by applying the start resistor. On the next semi-cycle
(negative) the conduction is done by the diode in anti-parallel with the crowbar thyristor.
As a consequence of the torque created by applying voltage to the armature, the motor
starts to increase rotation. As the rotation increases the frequency of the voltage induced at the
field and at the discharge resistor diminishes. If the brushless exciter field is excited, a DC
voltage starts to appear at the exciter armature rectifier output (between terminals TR_PR_A
and GND). The amplitude of this voltage increases as the motor increases its speed of rotation.
This voltage powers the internal electronic components of the GCDT-02. When the amplitude of
this voltage reaches 30 Vcc, the GCDT-02 will be properly energized.
When the GCDT-02 is energized, it furnishes the continuous firing of the crowbar
thyristors, not depending on the induced voltage, which improves significantly the motor
starting torque.
After being energized, the GCDT-02 also monitors the induced voltage at the start
resistor and compares its frequency with the slippage adjustment frequency. When the induced
frequency is less than the adjusted frequency (precondition 1) and the induced waveform is
crossing zero, at the transition between the thyristor crowbar conduction and the beginning of
conduction of the crowbar diode (precondition 2), the GCDT-02 will inhibit the firing of the
Crowbar thyristor and will fire the main field application thyristor (TR_PR). This will apply DC
current on the field terminals that will provide the magnetic coupling between the rotor and the
rotating field, placing the rotor into synchronism.
If the crowbar thyristor does not block its conduction at moment of field application, the relay
immediately fires the auxiliary thyristor (TR_AX), responsible for turning off the crowbar
thyristor.
The firing of the principal thyristor (TR_PR) ends the start up process, remaining in
conduction.
After the start up process is finished, with the motor in normal operation,if there is an
increase of the field voltage that exceeds the firing voltage of the crowbar, the (TR_CR)
thyristor will fire and the start up resistor will be applied. Immediately after, the auxiliary
thyristor (TR_AX) will fire , which will turn off the TR_CR as soon as the transient energy is
dissipated by the resistor.
Figure 1.2 shows a start up example. The upper wave form shows the voltage on the
motor field and the lower wave form shows the voltage at the start resistor.
At the beginning (before field application) the field voltage and the resistor voltage are
the same, because the crowbar thyristor is appying the start resistance to the circuit.
At the moment of synchronization, the TR_PR thyristor is fired and a DC voltage is
applied to the field. The crowbar thyristor continues conducting for a short period of time, and
is shortly after turned off by the auxiliary thyristor, remaining at zero voltage.
Note on the figure both preconditions for field application: The field is applied when the
slippage frequency decreases and the wave form is crossing zero on the transition from positive
to negative.
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FIGURE IGURE 1.2 1.2 - W - WAVE AVE F FORMS ORMS IN IN F FIELD IELD A APPLICATION PPLICATION
1.7 - Slipping Frequency Adjustment
The slippage point for synchronism can be adjusted through the “Dip Switch” located near
the LEDs (see figure 1.2). It's possible to adjust slippage from 0,49 to 5 Hz, where the 'Dip
Switch' switches combination determines the frequency.
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FIGURE IGURE 1.3 1.3 - D - DETAIL ETAIL OF OF THE THE S SLIPPING LIPPING A ADJUSTMENT DJUSTMENT “D “DIP IP S SWITCH WITCH”. ”.

GCDT-02 Rev. 05 of 2019-09-23
This table shows all possible “Dip Switch” switches combinations, with the respectives
frequency and slipping period values. Combining the 5 switch positions we can achieve a
frequency from 0.49 to 5 Hertz.
SWITCH POSITION SLIPPING
5 4 3 2 1 Period (ms) Frequency (Hz)
0 0 0 0 0 2060 0.49
1 0 0 0 0 2000 0.5
0 1 0 0 0 1940 0.52
1 1 0 0 0 1880 0.53
0 0 1 0 0 1820 0.55
1 0 1 0 0 1760 0.57
0 1 1 0 0 1700 0.59
1 1 1 0 0 1640 0.61
0 0 0 1 0 1580 0.63
1 0 0 1 0 1520 0.66
0 1 0 1 0 1460 0.68
1 1 0 1 0 1400 0.71
0 0 1 1 0 1340 0.75
1 0 1 1 0 1280 0.78
0 1 1 1 0 1220 0.82
1 1 1 1 0 1160 0.86
0 0 0 0 1 1100 0.91
1 0 0 0 1 1040 0.96
0 1 0 0 1 980 1.02
1 1 0 0 1 920 1.09
0 0 1 0 1 860 1.16
1 0 1 0 1 800 1.25
0 1 1 0 1 740 1.35
1 1 1 0 1 680 1.47
0 0 0 1 1 620 1.61
1 0 0 1 1 560 1.79
0 1 0 1 1 500 2
1 1 0 1 1 440 2.27
0 0 1 1 1 380 2.63
1 0 1 1 1 320 3.13
0 1 1 1 1 260 3.85
1 1 1 1 1 200 5
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GCDT-02 Rev. 05 of 2019-09-23
1.8 - LED Indicators
Figure 1.4 shows the GCDT-02 LEDs, and its functions are described below:
LED CR COND : Lights up when the Crowbar thyristor is conducting;
LED FIR PR : Lights up when the main thyristor (TR_PR) firing is active;
LED TURN OFF CR : Lights up when the Crowbar auxiliary shutdown thyristor firing is active;
LED FIR CR : Lights up when the Crowbar thyristor firing is active;
LED SOURCE OK : Indicates that the GCDT-02 is powered properly;
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FIGURE IGURE 1.4 1.4 - GCDT-02 LED' - GCDT-02 LED'S S

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2 -
2 -E EQUIPMENT QUIPMENT T TEST EST P PROCEDURE ROCEDURE
To test the GCDT-02, the following equipment are necessary:
•Variable DC power source from 20 to 300 Vdc;
•Function generator with variable amplitude signal up to 20V peak-to-peak;
•Three 10ohm/5W resistors;
•One 1ohm/5W resistor;
•One 1000ohm/500W resistor;
•One thyristor with current capacity larger than 1A and reverse voltage larger than 1000V;
•One diode with the same thyristor characteristics;
•One AC variable source from 0 to 480 Vac;
•Oscilloscope;
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FIGURE IGURE 2.1 2.1 - T - TEST EST C CIRCUIT IRCUIT

GCDT-02 Rev. 05 of 2019-09-23
2.1 -Test Procedure
2.1.1 - Assembly Preparation
1. Assembly the Figure 2.1 circuit;
2. Open the S1 and S2 switches;
3. Adjust the signal generator to square wave (duty cycle = 50%) with 7 Hz frequency and + /
- 10V amplitude;
4. Turn on the signal generator (G) in the terminals indicated in the figure;
5. Assembly one 10ohm/5W resistor in R1, R2 and R3;
6. Adjust the F1 source to 35 Vdc;
7. Turn on the S1 switch;
8. In this moment, the FONTE OK” (L5) LED and the “DISP CR” (L4) LED must light up, while
the “CR COND” (L1) LED must be blinking in the signal generator frequency;
9. With the oscilloscope, measure the voltage in R3 resistor (ponta em TR_CR_G e referência
em VRES). Must find a continuous amplitude signal from 5 to 8V;
10.Put the 1ohm resistor in parallel with the R3 resistor. The measured voltage must be
between 0,5 and 0,8V;
11.Measure the voltage in R1 and R2 resistors. Must be zero;
12.Position all dip switches in "0" (lowest frequency). If the firing frequency was already
adjusted, leave it as it is;
13. Lower the amplitude of the upper level of the function generator until the LED “CR COND”
(L1) stops blinking. The level of the function generator must be between 5 and 8 V when
this occurs.
2.1.2 - Field Application Test
14. Slowly lower the signal generator frequency until the “DISP PR” (L2) LED lights up (this LED
glows with lower intensity than the others) At this moment the “DISP CR” (L4) should turn
off, with LEDs “FONTE OK (L5) and “DISP PR” (L2) remaining on.;
15. Measure voltage on R1 using an oscilloscope (reference on TR_CR_A). The wave form
should be shaped as a square pulse train with duty cycle of approximately 10% , with 2ms
periods. The upper level of the square wave should be between 5 and 8V;
16. Place a 1ohm resistor in parallel with resistor R1. The measured voltage should be between
0,5 and 0,8 V;
17.Measure voltage on resistors R2 and R3. They should be equal to zero;
2.1.3 - Crowbar Disabling Test
18. Remove the 1ohm resistors in parallel with R2 and R3 and increase the amplitude of the
upper level of the square wave of the signal generator until reaching 10 V;
19. Measure voltage on R2 resistor using an oscilloscope (reference on VRES). A square wave
form in phase with the function generator and high level with amplitude of 5 to 8V should
appear;
20. Place a 1 ohm resistor in parallel with resistor R2. The measured high level voltage should
be between 0.5 and 0.8 V;
21. Measure the resistor R1 voltage. We must find the pulse train from item 15 modulated by
the frequency of the signal generator. The modulating wave must be out of phase by 180
degrees in relation to to the wave form of the function generator. That is, when the level of
function generator is high, the voltage at the resistor must be zero, and when the level of
function generator is low, the pulse train shold be observed;
22. The voltage at resistor R3 must be zero;
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GCDT-02 Rev. 05 of 2019-09-23
2.1.4 - Field Application Test With the Rotor Synchronized
23.Turn off the power supply to the module through switch S1;
24.Set the frequency of the signal generator to 7 Hz;
25.Turn on power supply to the module through switch S1;
26.Slowly increase the lower level of the square waveform until the “DISP PR” (L2) LED lights
up. When this happens the lower level of the waveform should have an amplitude between -
5 and -8 V;
27.Once again turn off the power supply to the module through switch S1;
28.Apply DC with an amplitude of 10 V on terminal "VRES" This can be done with the signal
generator, reducing the wave amplitude and increasing the offset;
29.Power the Module turning on switch S1. After a period between 3 and 5 seconds after the
switch was closed, the “DESL CR” (L3) LED should turn on and the “DISP CR” (L4) LED
should turn off. The “CR COND” (L1) LED should remain lit;
30.Using the function generator, lower the applied DC level applied to terminal VRES to 0V. At
this time, the “DISP PR” (L2) LED should light up and and the “FONTE OK” (L5) should
remain lit, while the other LEDs turn off;
2.1.5 - Test for Firing Interruption in Case of Voltage Drop
31. Slowly lower F1 power supply voltage until the “FONTE OK” (L5) LED turns off. When the
“FONTE OK” (L5) turns off the “DISP PR” (L2) should turn off and “DISP CR” (L4) should
light up.Increase the power supply voltage until the “FONTE OK” (L5) LED turns on. After a
time (5 seconds max.) the “DISP PR” (L2) LED should light up and the“DISP CR” (L4)
should turn off;
2.1.6 -Test for Crowbar Passive Firing
32.Adjust the F2 power supply amplitude to 0Vac;
33.Open S1 switch and close S2 switch;
34.Slowly increase voltage of F2 power supply, measuring with an oscilloscope the voltage at
the anode of the thyristor (reference on the cathode);
35. When the voltage reaches the passive firing level, there will be a cropping of the waveform
previously verified. These voltage level must be in accordance with the specificaion of the
equipment for this item.
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GCDT-02 Rev. 05 of 2019-09-23
3 -
3 - W WIRE IRE CONNECTIONS CONNECTIONS TO TO THE THE C CONNECTOR ONNECTOR
To perform the electrical connections, it is recommended to use cables with diameters ranging
from 1,5 to 2,5mm2 (with pressed-on terminals to increase its mechanical strength.
The wire connections to the connector must follow the steps below:
1. With a small screwdriver, press the desired orange color pin to open the spring (see
figure 3.2);
2. Put the wire end into the connector opening (see figure 3.1);
3. Relaease the orange color pin;
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FIGURE IGURE 3.2 3.2 - C - CABLES ABLES C CONNECTION ONNECTION F
FIGURE IGURE 3.1 3.1 - C - CABLES ABLES C CONNECTION ONNECTION
It is recommended to use a small
screwdriver
Screwdriver
Push the orange terminal
according to the Photo 3.2
Push
Cable in
position

GCDT-02 Rev. 05 of 2019-09-23
3.1 - Bracket for Wire Support
Optionally, a support for wire connection can be supplied together with the GCDT-02.
This support improves the wire attachment, increasing the mechanical rigidity and avoiding
damages due to vibration. The figure 3.3 shows an application example.
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FIGURE IGURE 3.3 3.3 - W - WIRE IRE C CONNECTIONS ONNECTIONS AND AND B BRACKET RACKET D DIMENSIONAL IMENSIONAL ( (MM MM) )

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3.2 -Mechanical Assembly
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GCDT-02 Rev. 05 of 2019-09-23
4 -
4 -D DIMENSIONS IMENSIONS ( (MM MM) )
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FIGURE IGURE 4.1 4.1 - D - DIMENSIONAL IMENSIONAL D DRAWING RAWING