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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GCDT-02 Rev. 05 of 2019-09-23
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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GCDT-02 Rev. 05 of 2019-09-23
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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F
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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