Automation Direct DURApulse GS4 User Manual

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DURApulse GS4 AC Drive User Manual

First Edition, Revision A

GS4_UMW

Page 2

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Warnings and Trademarks

~ 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.

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.

DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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~ AVERTISSEMENT ~

Nous vous remercions d’avoir acheté l’équipement d’automatisation de Automationdirect.com®, en faisant des affaires comme AutomationDirect. Nous tenons à ce que votre nouvel équipement d’automatisation fonctionne en toute sécurité. Toute personne qui installe ou utilise cet équipement doit lire la présente publication (et toutes les autres publications pertinentes) avant de l’installer ou de l’utiliser.

Afin de réduire au minimum le risque d’éventuels problèmes de sécurité, vous devez respecter tous les codes locaux et nationaux applicables régissant l’installation et le fonctionnement de votre équipement. Ces codes diffèrent d’une région à l’autre et, habituellement, évoluent au fil du temps. Il vous incombe de déterminer les codes à respecter et de vous assurer que l’équipement, l’installation et le fonctionnement sont conformes aux exigences de la version la plus récente de ces codes.

Vous devez, à tout le moins, respecter toutes les sections applicables du Code national de prévention des incendies, du Code national de l’électricité et des codes de la National Electrical Manufacturer’s Association (NEMA). Des organismes de réglementation ou des services gouvernementaux locaux peuvent également vous aider à déterminer les codes ainsi que les normes à respecter pour assurer une installation et un fonctionnement sûrs.

L’omission de respecter la totalité des codes et des normes applicables peut entraîner des dommages à l’équipement ou causer de graves blessures au personnel. Nous ne garantissons pas que les produits décrits dans cette publication conviennent à votre application particulière et nous n’assumons aucune responsabilité à l’égard de la conception, de l’installation ou du fonctionnement de votre produit.

Nos produits ne sont pas insensibles aux défaillances et ne sont ni conçus ni fabriqués pour l’utilisation ou la revente en tant qu’équipement de commande en ligne dans des environnements dangereux nécessitant une sécurité absolue, par exemple, l’exploitation d’installations nucléaires, les systèmes de navigation aérienne ou de communication, le contrôle de la circulation aérienne, les équipements de survie ou les systèmes d’armes, pour lesquels la défaillance du produit peut provoquer la mort, des blessures corporelles ou de graves dommages matériels ou environnementaux («activités à risque élevé»). La société AutomationDirect nie toute garantie expresse ou implicite d’aptitude à l’emploi en ce qui a trait aux activités à risque élevé.

Pour des renseignements additionnels touchant la garantie et la sécurité, veuillez consulter la section Modalités et conditions de notre documentation. Si vous avez des questions au sujet de l’installation ou du fonctionnement de cet équipement, ou encore si vous avez besoin de renseignements supplémentaires, n’hésitez pas à nous téléphoner au 770-844-4200.

Cette publication s’appuie sur l’information qui était disponible au moment de l’impression. À la société AutomationDirect, nous nous efforçons constamment d’améliorer nos produits et services. C’est pourquoi nous nous réservons le droit d’apporter des modifications aux produits ou aux publications en tout temps, sans préavis ni quelque obligation que ce soit. La présente publication peut aussi porter sur des caractéristiques susceptibles de ne pas être offertes dans certaines versions révisées du produit.

Marques de commerce

La présente publication peut contenir des références à des produits fabriqués ou offerts par d’autres entreprises. Les désignations des produits et des entreprises peuvent être des marques de commerce et appartiennent exclusivement à leurs propriétaires respectifs. AutomationDirect nie tout intérêt dans les autres marques et désignations.

Nulle partie de ce manuel ne doit être copiée, reproduite ou transmise de quelque façon que ce soit sans le consentement préalable écrit de la société Automationdirect.com® Incorporated. AutomationDirect conserve les droits exclusifs à l’égard de tous les renseignements contenus dans le présent document.

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DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Warnings

Warning: read This manual Thoroughly before using durapulse series aC moTor drives.

Warning: aC inpuT poWer musT be disConneCTed before performing any mainTenanCe. do noT

ConneCT or disConneCT Wires or ConneCTors While poWer is applied To The CirCuiT. mainTenanCe musT be performed only by a qualified TeChniCian.

Warning: There are highly sensiTive mos ComponenTs on The prinTed CirCuiT boards, and These

ComponenTs are espeCially sensiTive To sTaTiC eleCTriCiTy. To avoid damage To These ComponenTs, do noT TouCh These ComponenTs or The CirCuiT boards WiTh meTal objeCTs or your bare hands.

Warning: a Charge may sTill remain in The dC-link CapaCiTor WiTh hazardous volTages, even if The

poWer has been Turned off. To avoid personal injury, do noT remove The Cover of The aC drive unTil all “display led” lighTs on The digiTal keypad are off. please noTe ThaT There are live ComponenTs exposed WiThin The aC drive. do noT TouCh These live parTs.

Warning: ground The durapulse aC drive using The ground Terminal. The grounding meThod musT

Comply WiTh The laWs of The CounTry Where The aC drive is To be insTalled. refer To “basiC Wiring

diagram” in ChapTer 2.

Warning: The mounTing enClosure of The aC drive musT Comply WiTh en50178. live parTs shall be

arranged in enClosures or loCaTed behind barriers ThaT meeT aT leasT The requiremenTs of The proTeCTive

Type ip20. The Top surfaCe of The enClosures or barrier ThaT is easily aCCessible shall meeT aT leasT The

requiremenTs of The proTeCTive Type ip40. users musT provide This environmenT for durapulse series

aC drive.

Warning: The aC drive may be desTroyed beyond repair if inCorreCT Cables are ConneCTed To The inpuT/

ouTpuT Terminals. never ConneCT The aC drive ouTpuT Terminals T1, T2, and T3 direCTly To The aC main CirCuiT poWer supply.

all durapulse drives require a symmeTriCal 3-phase poWer sourCe. do noT ConneCT Them To grounded, CenTer-Tapped delTa Transformers of The Type TypiCally used for

lighTing CirCuiTs.

DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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DURApUlse GS4 AC Drive USer MAnUAl reviSion HiStory

Please include the Manual nuMber and the Manual issue, both shown below, when

coMMunicating with technical suPPort regarding this Publication.

Manual nuMber: gs4_uMw

issue: First edition, revision a

issue date: 10/20/2017

Publication History

Issue Date Description of Changes

First Edition 10/18/2017 Original Issue

Ch1: Drive specifications Ch4: Analog input parameter examples, Parameter explanations Ch8: Various explanation revisions, screen capture examples, etc.

1st Ed, Rev A 10/20/2017

AppxA: Fuses AppxB: GS4-06CDD Digital Inputs Wiring AppxC: Added AI1 note AppxF: P7.25 diagrams

1st Ed, Rev A - 10/20/2017 – DURApulse GS4 AC Drive User Manual H–1

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User Manual Revision History

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H–2

DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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DURApUlse GS4 AC Drive USer MAnUAl TAble of ConTenTS

ConTenTS

arnings and Trademarks

~ WARNING ~. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W–1

Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W–1

~ AVERTISSEMENT ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W–2

Marques de commerce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W–2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W–3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W–1

dUra

pUlse

gs4 U

pUlse

gs4 aC d

HapTer

1: g

User Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Overview of this Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Who Should Read This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Supplemental Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Special Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Purpose of AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Selecting the Proper Drive Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Determine Motor Full-Load Amperage (FLA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Determine Motor Overload Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Determine Application Type; Constant Torque or Variable Torque . . . . . . . . . . . . . . . . . . 1–3

Installation Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Determine Maximum Enclosure Internal Temperature . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

Derate Output Current Based on Carrier Frequency (if necessary) . . . . . . . . . . . . . . . . . . 1–6

dura

pulse

Storage and Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

dura

pulse

230V Class – Constant Torque – (Model-Specific Specifications) . . . . . . . . . . . . . . . . . . 1–10

230V Class – Variable Torque – (Model-Specific Specifications) . . . . . . . . . . . . . . . . . . . 1–11

460V Class – Constant & Variable Torque – (Model-Specific Specifications) . . . . . . . . . . . . 1–12

Specifications Applicable to All GS4 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14

Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15

Drive Package Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15

Model Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16

Nameplate Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16

Unpacking Your GS4 dura

Lifting Eye Locations and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17

Unpacking the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19

ser manUal revision HisTory

rive User manUal Table of ConTenTs

eTTing sTarTing

GS4 AC Drive Environmental Information. . . . . . . . . . . . . . . . . . . . . . . . 1–9

GS4 AC Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

pulse

AC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17

. . . . . . . . . . . . . . . . . . . . . H–1

. . . . . . . . . . . . . . ToC–1

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

TOC–1

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Table of Contents

HapTer

2: i

nsTallaTion and Wiring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

Drive Models by Frame Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

Minimum Clearances and Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Minimum Clearance Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Airflow and Power Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7

Circuit Connections – RFI Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14

RFI Jumper Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14

Isolating Main Power from Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15

Floating Ground System (IT Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16

Asymmetric Ground System (Corner Grounded TN Systems) . . . . . . . . . . . . . . . . . . . . 2–16

Circuit Connections – Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17

Danger!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17

Wiring Terminal Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20

Control Terminal Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20

Removing the Control Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21

Main Circuit Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22

Main Terminal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22

Wiring Terminal Connector Dimensions – Main-Circuit Terminals . . . . . . . . . . . . . . . . . . 2–24

Main Terminal Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28

Main Circuit Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30

Control Circuit Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32

Control Terminal Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32

Control Terminal Block Diagram & Wiring Specifications . . . . . . . . . . . . . . . . . . . . . . 2–34

Control Terminal Wiring Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–34

Control Circuit Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–35

Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–35

Full I/O with Sinking Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–36

Full I/O with Sourcing Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37

TOC–2

HapTer

3: k

The dura

eypad operaTion and QUiCksTarT

pulse

GS4 Digital Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

. . . . . . . . . . . . . . . . . . . . . . 3–1

GS4 Start-Up Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

Status Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

Menu Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

Param Setup - Parameter Setup Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

Quick-Start – Quick-Start Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6

Keypad Lock - Keypad Lock Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10

Fault Record - Fault Record Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11

PLC - PLC Function Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12

Copy Param - Copy Parameters Page (Keypad Copy). . . . . . . . . . . . . . . . . . . . . . . . . 3–13

Copy PLC - Copy PLC Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14

Displ Setup - Display Setup Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15

Time Setup - Time Setup Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15

Language - Language Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15

Start-up - Start-up Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16

Keypad Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Table of Contents

HapTer

4: aC d

DURA

pulse

Motor Parameters Summary (P0.xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

Ramps Parameters Summary (P1.xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

V/Hz Parameters Summary (P2.xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

Digital Parameters Summary (P3.xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6

Analog Parameters Summary (P4.xx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10

Presets Parameters Summary (P5.xx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14

Protection Parameters Summary (P6.xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15

PID Parameters Summary (P7.xx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19

Display Parameters Summary (P8.xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–21

Serial Communication Parameters Summary (P9.xx) . . . . . . . . . . . . . . . . . . . . . . . . . 4–24

Pump Parameters Summary (P10.xx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–29

Fault Parameters Summary (P11.xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30

DURA

pulse

Explanation of Parameter Details format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33

Group P0.xx Details – Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33

Group P1.xx Details – Ramps Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39

Group P2.xx Details – V/Hz Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–49

Group P3.xx Details – Digital Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–63

Group P4.xx Details – Analog Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–93

Analog Input Parameter Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–112

Group P5.xx Details – Presets Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–123

Group P6.xx Details – Protection Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–125

Group P7.xx Details – PID Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–164

Group P8.xx Details – Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–174

Group P9.xx Details – Serial Communication Parameters . . . . . . . . . . . . . . . . . . . . . .4–181

Block Transfer Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–192

Group P10.xx Details – Pump Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–193

Pump Parameters Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–194

Timing Charts for Circulative Control Modes P10.01 through P10.08. . . . . . . . . . . . . . . .4–197

Terminal Specifications for GS4-06TR (Optional Six-Relay Output Card) . . . . . . . . . . . . . .4–203

Wiring Diagrams for Cyclical Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–203

Group P11.xx Details – Fault Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–206

rive parameTers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

GS4 Parameter Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

GS4 Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33

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erial CommUniCaTions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

Communications Parameters Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

Summary – Serial Communication Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

Summary – Block Transfer Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5

Serial Modbus Status Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

Status Addresses (Read Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

Serial Communications Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

Serial Communications Connectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

Minimum AC Drive Parameter Settings For Serial Communication . . . . . . . . . . . . . . . . . . 5–8

Common Third-Party Modbus RTU Masters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9

AutomationDirect PLCs as Modbus Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9

Connecting Communication Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10

Detailed Serial Modbus Communication Information . . . . . . . . . . . . . . . . . . . . . . . 5–12

Data Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12

Communication Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13

CMD (command code) and DATA (data characters) . . . . . . . . . . . . . . . . . . . . . . . . . 5–14

BACnet Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18

About BACnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18

Parameter Summary for BACnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18

GS4 BACnet Object and Property . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19

Steps to Setup the GS4 Parameters for BACnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–23

BACnet Protocol Implementation Conformance Statement . . . . . . . . . . . . . . . . . . . . . 5–24

HapTer

6: m

ainTenanCe and TroUblesHooTing

. . . . . . . . . . . . . . . . . . . . . 6–1

Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

Monthly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

Recharge Capacitors (for drives not in service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

Recommended Inspection Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8

Warning Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8

Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16

Typical AC Drive Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26

Grease and Dirt Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26

Fiber Dust Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27

Corrosion Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28

Industrial Dust Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–29

Wiring and Installation Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–30

Digital Input/Output Terminal Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–31

HapTer

7: gs

ofT

2 – g

eTTing sTarTed

. . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

GS4 Drive Configuration Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2

System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2

Installation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

System Requirement Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

Software Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4

Opening GSoft2 Software Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6

Software Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7

Firmware Upgrade Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10

GSoft2 Help File Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10

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8: gsl

Purpose of This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

For More Detailed Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

GSLogic Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

GS4 PLC Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

Notes on Using GSLogic, the GS4 PLC, and the GS4 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4

Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6

Connect to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6

Installation of GSLogic Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

About Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

Software and Online Help Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

Installing GSLogic Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–10

Program Writing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–12

Connecting GSLogic PC to GS4 PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–12

Basic Ladder Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–17

Program Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–19

Program Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–20

GS4 GSLogic Program Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–21

a: a

EMI Input Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2

EMI Filter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3

EMI Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5

Reflective Wave Phenomenon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–6

Recommended Motor Cable Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–6

Motor Cable Length Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–7

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–9

Line/Load Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–10

Line/Load Reactors Selection Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–10

DC Reactors (Choke) Specification Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–12

Line/Load Reactor Specification Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–13

Line Reactor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–14

Line Reactor Applications and Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–20

Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–23

Braking Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–23

USB to RS-485 PC Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–24

USB-485M to GS4 Wiring and Pin-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–24

Conduit Box Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–25

Conduit Box Installation – Frames D0 and D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–26

Conduit Box Installation – Frame E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–27

Conduit Box Installation – Frame F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–28

Conduit Box Installation – Frame G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–29

Flange Mounting Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–31

Flange Mounting Kits – Frame A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–31

Flange Mounting Kits – Frame B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–34

Flange Mounting Kits – Frame C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–36

Optional Cutout Dimensions for Built-in Flange Mounting . . . . . . . . . . . . . . . . . . . . . . . . A–38

Spare Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–39

GS4-KPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–39

Keypad Panel Mounting Kit GS4-BZL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–41

Spare Fan Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–43

Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–47

ogiC inTrodUCTion

CCessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a–1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2

Removing the Card Slot Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2

Option Card Installation and Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4

Optional I/O Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5

Optional Communications Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–8

b: o

pTional

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4

GS4-06CDD Combo I/O card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5

GS4-06NA Input card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–7

GS4-06TR Output card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–7

GS4-MODTCP and GS4-CM-ENETIP IP Address and Network Configuration. . . . . . . . . . . . . B–9

GS4-CM-MODTCP Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–10

GS4-CM-MODTCP LED Indicators and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . B–12

GS4-CM-MODTCP Common Communication Parameters . . . . . . . . . . . . . . . . . . . . . . B–13

GS4-CM-MODTCP Control Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–14

GS4-CM-MODTCP Status Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–15

GS4-CM-ENETIP Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–16

GS4-CM-ENETIP LED Indicators and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . B–17

GS4-CM-ENETIP Common Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–18

GS4-CM-ENETIP EtherNet/IP I/O Messaging (Implicit Messaging) . . . . . . . . . . . . . . . . . B–19

GS4-CM-ENETIP Explicit Messaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–22

i/o

and CommUniCaTion Cards

. . . . . . . . . . . . . . . . . . b–1

ppendix

C: a

nalog and digiTal

i/o p

arameTer maps

. . . . . . . . . . . . . . . . . . C–1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–2

GS4 Digital Inputs – Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–3

GS4 Digital Outputs – Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–4

GS4 Digital Inputs – Option Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–5

GS4 Digital Outputs – Option Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–6

GS4 Digital Outputs – Virtual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–7

GS4 Analog Common Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–8

GS4 Analog Input 1 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–8

GS4 Analog Input 2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–9

GS4 Analog Input 3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–10

GS4 Analog Output 1 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–11

GS4 Analog Output 2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–11

GS4 Frequency Output Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–12

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Magenta text indicates a question or something that needs an answer or decision. . . . . . . . D–1

Appendix D Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–2

PLC Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–4

Communication with GS4 Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–10

Program Examples Using AutomationDirect CLICK PLC . . . . . . . . . . . . . . . . . . . . . . D–18

d: a

UTomaTiondireCT

Sinking/Sourcing Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–2

Drive Wired with DC Sinking Inputs (PLC output card is sourcing) . . . . . . . . . . . . . . . . . . D–4

Drive Wired with DC Sourcing Inputs (PLC output card is sinking) . . . . . . . . . . . . . . . . . . D–4

Drive Wired with DC Sinking Outputs (PLC input card is sourcing) . . . . . . . . . . . . . . . . . . D–5

Drive Wired with DC Sourcing Outputs (PLC input card is sinking) . . . . . . . . . . . . . . . . . . D–5

Drive Relay Outputs Wired with Sinking PLC Modules . . . . . . . . . . . . . . . . . . . . . . . . . D–6

Drive Relay Outputs Wired with Sourcing PLC Modules . . . . . . . . . . . . . . . . . . . . . . . . D–6

Drive Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–7

Analog Input Wired for Voltage and Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–7

Drive Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–8

Analog Output Wired for Voltage and Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–8

Drive Frequency Output (High-speed pulse output) . . . . . . . . . . . . . . . . . . . . . . . . . . D–9

Getting Started. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–10

Serial Modbus Monitoring and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–10

ModTCP (Ethernet) Monitor and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–15

EtherNet/IP Monitor and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–16

GS4-CM-ENETIP EtherNet/IP I/O Messaging (Implicit Messaging) . . . . . . . . . . . . . . . . . D–16

Modbus RTU CLICK Program Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–18

plC p

rogram examples

. . . . . . . . . . . . . . . . . d–1

ppendix

e: s

afe TorQUe off

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e–1

Safe Function Failure Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–2

Safe Torque Off Terminal Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–2

Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3

Internal STO Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3

Control Loop Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3

STO Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–4

Operating Sequence Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–5

STO P6.71=0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–5

STO P6.71=0, P6.29=1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–5

STO P6.71=1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–5

STL1 P6.71=1, P6.29=0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–6

STL2 P6.71=1, P6.29=1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–6

Error Codes for STO Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–6

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

TOC–7

Page 16

Table of Contents

ppendix

PID Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–2

Common Applications for PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–5

Concept of PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–6

Tuning Example for PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–8

DURA

GS4 Parameters Involved in PID Control – Summary. . . . . . . . . . . . . . . . . . . . . . . . F–10

GS4 Parameters Involved in PID Control – Details . . . . . . . . . . . . . . . . . . . . . . . . . F–11

f: pid C

PID Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–2

PID Control Analogy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–3

Forward-Acting vs. Reverse-Acting PID Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–3

Definitions and Information for High-Functioning PID Parameters . . . . . . . . . . . . . . . . F–4

Proportional Gain (P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–6

Integral Time (I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–6

Derivative Value (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–7

Proportional Integral Control (PI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–7

Proportional Differential Control (PD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–7

Proportional Integral Differential Control (PID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–7

pulse

onTrol

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . f–1

GS4 and GS3 PID Parameter Comparisons. . . . . . . . . . . . . . . . . . . . . . . . F–9

TOC–8

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 17

Chapter

Getting Started

able of ConTenTs

User Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2

Overview of this Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Who Should Read This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Supplemental Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Special Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Purpose of AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3

Selecting the Proper Drive Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3

Determine Motor Full-Load Amperage (FLA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Determine Motor Overload Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Determine Application Type; Constant Torque or Variable Torque . . . . . . . . . . . . . . . . . . . . 1–3

Installation Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Determine Maximum Enclosure Internal Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

Derate Output Current Based on Carrier Frequency (if necessary) . . . . . . . . . . . . . . . . . . . . 1–6

dura

Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15

Model Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16

Nameplate Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16

Unpacking Your GS4 dura

pulse

GS4 AC Drive Environmental Information . . . . . . . . . . . . . . . . . . . . . . . .1–9

Storage and Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

pulse

GS4 AC Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

230V Class – Constant Torque – (Model-Specific Specifications) . . . . . . . . . . . . . . . . . . . . .1–10

230V Class – Variable Torque – (Model-Specific Specifications) . . . . . . . . . . . . . . . . . . . . . .1–11

460V Class – Constant & Variable Torque – (Model-Specific Specifications) . . . . . . . . . . . . . . . 1–12

Specifications Applicable to All GS4 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14

Drive Package Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15

pulse

AC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17

Lifting Eye Locations and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–17

Unpacking the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–19

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 1–1

Page 18

Chapter 1: Getting Started

User ManUal Overview

overvieW of This publiCaTion

The DURApUlse GS4 AC Drive User Manual describes the installation, configuration, and methods of operation of the DURApUlse GS4 Series AC Drive.

Who should read This manual

This manual contains important information for those who will install, maintain, and/or operate any of the GS4 Series AC Drives.

supplemenTal publiCaTions

The National Electrical Manufacturers Association (NEMA) publishes many different documents that discuss standards for industrial control equipment. Global Engineering Documents handles the sale of NEMA documents. For more information, you can contact Global Engineering Documents at: 15 Inverness Way East

TeChniCal supporT

By Telephone: 770-844-4200

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.

Englewood, CO 80112-5776 1-800-854-7179 (within the U.S.) 303-397-7956 (international) www.global.ihs.com

(Mon.–Fri., 9:00 a.m.–6:00 p.m. E.T.)

speCial symbols

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

WARNING: WheN you see the “exclAmAtIoN mARk” IcoN IN the left-hANd mARGIN, the pARAGRAph to

Its ImmedIAte RIGht WIll be A WARNING. thIs INfoRmAtIoN could pReveNt INjuRy, loss of pRopeRty, oR eveN deAth (IN extReme cAses).

Page 1–2

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 19

PUrPOse Of aC Drives

AC drives are generally known by many different names: Adjustable Frequency Drives (AFD), Variable Frequency Drives (VFD), and Inverters. Drives are used primarily to vary the speed of three phase AC induction motors, and they also provide non-emergency start and stop control, acceleration and deceleration, and overload protection. By gradually accelerating the motor, drives can reduce the amount of motor startup inrush current.

AC drives function by converting incoming AC power to DC, which is then synthesized back into three phase output power. The voltage and frequency of this synthesized output power is directly varied by the drive, where the frequency determines the speed of the three phase AC induction motor.

seleCting the PrOPer Drive rating

deTermine moTor full-load amperage (fla)

Motor FLA is located on the nameplate of the motor. NOTE: FLA of motors that have been rewound may be higher than stated.

deTermine moTor overload requiremenTs

Many applications experience temporary overload conditions due to starting requirements or impact loading. Most AC drives are designed to operate at 150% overload for 60 seconds. If the application requires an overload greater than 150% or longer than 60 seconds, the AC drive must be oversized.

NOTE: Applications that require replacement of existing motor starters with AC drives may require up to 600% overload.

Chapter 1: Getting Started

deTermine appliCaTion Type; ConsTanT Torque or variable Torque

This torque requirement has a direct effect on which drive to select. Variable Torque applications are generally easier to start; typically fans and pumps. Most other applications outside fans and pumps fall into the Constant Torque category (machine control, conveyors, etc.). If you are unsure of the application, assume Constant Torque. The specification, derating, and selection tables are generally segregated by Constant Torque and Variable Torque.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 1–3

Page 20

Chapter 1: Getting Started

GS4 Derating for Altitude

40°C for UL Type 1 / IP 20 & UL Open Type / IP20 Side-by-Side

seleCTing The proper drive raTing (ConTinued)

insTallaTion alTiTude

AC drives rely on air flow for cooling. As the altitude increases, the air becomes less dense, and this drop in air density decreases the cooling properties of the air. Therefore, the AC drive must be oversized to compensate for the decrease in cooling. Most AC drives are designed to operate at 100% capacity at altitudes up to 1000 meters.

NOTE: For use above 1000m, the AC drive must be derated as described below.

deraTe ouTpuT CurrenT based on alTiTude above 1000 meTers

•

If the AC drive is installed at an altitude of 0~1000m, follow normal operation restrictions.

•

If installed at an altitude of 1000~3000m, decrease 1% of the rated current or lower 0.5°C of temperature for every 100m increase in altitude.

•

Maximum altitude for Corner Grounded is 2000m.

Rating (%) at Standard Ambient Temperature*

100

0 500 1500 25001000 2000 3000

Altitude (m)

*Standard Ambient Temperature = 50°C for UL Open Type / IP20 *Standard Ambient Temperature =

Ta at Rating = 100%

UL Open Type / IP20

UL Open Type / IP20 Side-by-Side

UL Type 1 / IP20

Page 1–4

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 21

Chapter 1: Getting Started

Ambient Temperature (°C)

seleCTing The proper drive raTing (ConTinued)

deTermine maximum enClosure inTernal TemperaTure

AC drives generate a significant amount of heat and will cause the internal temperature of an enclosure to exceed the rating of the AC drive, even when the ambient temperature is less than 104°F (40°C). Enclosure ventilation and/or cooling may be required to maintain a maximum internal temperature of 104°F (40°C) or less. Ambient temperature measurements/calculations should be made for the maximum expected temperature. When permissible, flange mounting the AC drive (mounting with the drive heatsink in open ambient air) can greatly reduce heating in the enclosure.

For use above 104°F (40°C), the AC drive must be derated as described below.

deraTe ouTpuT CurrenT based on TemperaTure above 104°f (40°C)

Drive Derating by Temperature and Protection Level

Protection Level Derating

When the GS4 drive is operating at rated current, the ambient temperature has to be

UL Type 1 / IP20 *

UL Open Type / IP20 *

* For more information about environmental ratings, refer to the “Operating Temperature and

Protection Level” table on page 1–9 of this chapter.

between -10°C and +40°C. When ambient temperature exceeds 40°C, decrease the rated current by 2% for every 1°C temperature increase. Maximum allowable temperature is 60°C.

When the GS4 drive is operating at rated current, the ambient temperature has to be between -10°C and +50°C. When ambient temperature exceeds 50°C, decrease the rated current by 2% for every 1°C temperature increase. Maximum allowable temperature is 60°C.

Derating for Ambient Temperature

100%

90%

80%

70%

60%

50%

Output Current Rating(A)

40%

30 35 40 45 50 55 60

UL Open-Type / IP 20

UL TYPE1 / IP20 UL OPEN TYPE / IP 20 side-by-side

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 1–5

Page 22

Chapter 1: Getting Started

seleCTing The proper drive raTing (ConTinued)

deraTe ouTpuT CurrenT based on Carrier frequenCy (if neCessary)

Carrier frequenCy effeCTs

AC Drives rectify the incoming 50 or 60Hz line power resulting in DC power at 0Hz. The resulting DC power is then pulse-width modulated and supplied to the motor by the drive’s power electronics. IGBTs invert the DC power, simulating a sine wave at the desired frequency (that’s what allows variable speed in AC induction motors). The speed at which the IGBTs are turned ON and OFF is called Carrier Frequency. In AC drives, the Carrier Frequency can range from 2kHz to 15kHz. The Carrier Frequency can be adjusted in most AC Drives.

There are trade-offs between choosing High Carrier Frequencies and Low Carrier Frequencies.

benefiTs of higher Carrier frequenCies:

•

Better efficiency (lower harmonic losses) in the motor

•

Lower audible noise

benefiTs of loWer Carrier frequenCies:

•

Better efficiency in the drive

•

Lower EMI (electrical noise)

•

Reduced reflective wave peak voltage

As a general rule, the Carrier Frequency should be set as low as possible without creating unacceptable audible noise in the motor. Smaller systems can have higher Carrier Frequencies, but larger drives (>20 or 30hp) should not have Carrier Frequencies set higher than 6kHz. Heavy Duty applications typically run around 2~4kHz.

Page 1–6

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 23

Chapter 1: Getting Started

315

Ratio(%)

GS4-21P0 – GS4-2015

315

Ratio(%)

GS4-21P0 – GS4-2015

315

Ratio(%)

GS4-41P0 – GS4-4020

315

Ratio(%)

GS4-41P0 – GS4-4020

seleCTing The proper drive raTing (ConTinued)

Carrier frequenCy deraTing (ConTinued)

These Variable Torque (VT) and Constant Torque (CT) derating curves are for drives with 3-phase input power. The 230VAC, CT curves also apply equally whether the drive is supplied with 3-phase or 1-phase input power.

230v variable Torque Carrier frequenCy deraTing

For 230V Variable Torque

VT/CT Duty Selection P6.34 = 0 Method of Derating P6.33 = 0, 1, or 2 50°C UL Open Type 40°C UL Type 1 or Open Type side-by-side

For 230V Variable Torque

VT/CT Duty Selection P6.34 = 0 Method of Derating P6.33 = 0 or 2 40°C UL Open Type 30°C UL Type 1 or Open Type side-by-side

GS4-2020 – GS4-2050 GS4-2060 – GS4-2100

110

100

468101214

579111

100

Fc (kHz)

460v variable Torque Carrier frequenCy deraTing

For 460V Variable Torque

VT/CT Duty Selection P6.34 = 0 Method of Derating P6.33 = 0, 1, or 2 50°C UL Open Type 40°C UL Type 1 or Open Type side-by-side

GS4-4025 – GS4-4075 GS4-4100 – GS4-4300

110

For 460V Variable Torque

VT/CT Duty Selection P6.34 = 0 Method of Derating P6.33 = 0 or 2 40°C UL Open Type 30°C UL Type 1 or Open Type side-by-side

GS4-2020 – GS4-2050 GS4-2060 – GS4-2100

110

468101214

579111

Fc (kHz)

GS4-4025 – GS4-4075 GS4-4100 – GS4-4300

110

100

468101214

579111

100

468101214

579111

Fc (kHz)

Reference Chapter 4, Parameters, for complete descriptions of parameters P6.33 and P6.34.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Fc (kHz)

Page 1–7

Page 24

Chapter 1: Getting Started

315

Ratio(%)

GS4-21P0 – GS4-2015

315

Ratio(%)

GS4-21P0 – GS4-2015

315

Ratio(%)

GS4-41P0 – GS4-4020

315

Ratio(%)

GS4-41P0 – GS4-4020

seleCTing The proper drive raTing (ConTinued)

Carrier frequenCy deraTing (ConTinued)

230v ConsTanT Torque Carrier frequenCy deraTing

For 230V Constant Torque

VT/CT Duty Selection P6.34 = 1 Method of Derating P6.33 = 0, 1, or 2 50°C UL Open Type 40°C UL Type 1 or Open Type side-by-side

For 230V Constant Torque

VT/CT Duty Selection P6.34 = 1 Method of Derating P6.33 = 0 or 2 40°C UL Open Type 30°C UL Type 1 or Open Type side-by-side

GS4-2020 – GS4-2050 GS4-2060 – GS4-2100

110 100

90 80 70 60 50 40

268101214

579111

110 100

90 80 70 60 50 40

Fc (kHz)

460v ConsTanT Torque Carrier frequenCy deraTing

For 460V Constant Torque

VT/CT Duty Selection P6.34 = 1 Method of Derating P6.33 = 0, 1, or 2 50°C UL Open Type 40°C UL Type 1 or Open Type side-by-side

For 460V Constant Torque

VT/CT Duty Selection P6.34 = 1 Method of Derating P6.33 = 0 or 2 40°C UL Open Type 30°C UL Type 1 or Open Type side-by-side

GS4-4025 – GS4-4075 GS4-4100 – GS4-4300

110 100

90 80 70 60 50 40

268101214

579111

110 100

90 80 70 60 50 40

Fc (kHz)

GS4-2020 – GS4-2050 GS4-2060 – GS4-2100

579111

268101214

Fc (kHz)

GS4-4025 – GS4-4075 GS4-4100 – GS4-4300

579111

268101214

Fc (kHz)

Page 1–8

Reference Chapter 4, Parameters, for complete descriptions of parameters P6.33 and P6.34.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 25

Chapter 1: Getting Started

Only the circled area is IP00.

durapulse gs4 aC Drive envirOnMental infOrMatiOn

sTorage and TransporTaTion

AC drives should be kept in the shipping cartons or crates until they are installed. In order to retain the warranty coverage, they should be stored as described below if not to be installed and used within three months.

•

Store in a clean and dry location free from direct sunlight and corrosive fumes.

•

Store within environmental conditions shown below in the “Environmental Conditions” table.

•

DO NOT store in an area with rapid changes in temperature , to avoid condensation and frost.

•

DO NOT place directly on the ground.

If the drive is stored or is otherwise unused for more than a year, the drive’s internal DC link capacitors should be recharged before use. Otherwise, the capacitors may be damaged when the drive starts to operate. We recommend recharging the capacitors of any unused drive at least once per year. (Refer to Chapter 6, “Maintenance and Troubleshooting” for information about recharging DC link capacitors.)

environmenTal CondiTions

Environmental Conditions for GS4 AC Drives

Condition Operation Storage Transportation Installation Location Ambient Temperature Relative Humidity Air Pressure

Pollution Level

Altitude

Package Drop

Vibration

Impact

Installation Orientation

IEC60364-1/IEC60664-1 Pollution degree 2, Indoor use only n/a n/a

see separate Operating Temperature table below -25°C to +70°C

Max 90%, non-condensing, non-frozen Max 95%, non-condensing, non-frozen

86 to 106 kPa 70 to 106 kPa

IEC721-3-3, no concentrate

Class 3C2; Class 3S2 Class 2C2; Class 2S2 Class 1C2; Class 1S2

(see separate derating section for altitudes of 1000–3000m)

0~1000m

n/a

1.0mm, peak to peak value range from 2Hz to 13.2 Hz; 0.7G~1.0G range from 13.2Hz to 55Hz; 1.0G range from 55Hz to 512 Hz. Comply with IEC 60068-2-6

IEC/EN 60068-2-27

Max allowed offset angle ±10° (from vertical installation position)

n/a n/a

ISTA procedure 1A(according to weight)

IEC60068-2-31

10° 10°

Frame Size Top cover Conduit Box Protection Level

A~C

D0~G

230V: 1.0~30 hp 460V: 1.0~40 hp

230V: >30hp 460V: >40hp

* Only the exposed terminal blocks are IP00; the other components are IP20

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Operating Temperature and Protection Level

Operating Temperature

With top cover removed

With top cover in place IP20 / UL Type1 / NEMA1 -10~40°C [14~104°F]

N/A

Standard conduit plate

With conduit box

Without conduit box

IP20 / UL Open Type -10~50°C [14~122°F]

IP20 / UL Type1 / NEMA1 -10~40°C [14~104°F]

IP00 / IP20 / UL Open Type *

Other parts are IP20

-10~50°C [14~122°F]

Page 1–9

Page 26

Chapter 1: Getting Started

durapulse gs4 aC Drive sPeCifiCatiOns

230v Class – ConsTanT Torque – (model-speCifiC speCifiCaTions)

GS4 230V Class Constant-Torque Specifications; Frame Sizes A~B (Model-Specific Specifications)

For Use With Three-Phase Motors Only

Model Name: GS4-xxxx 21P0 22P0 23P0 25P0 27P5 2010 2015 Frame Size A B

Max Motor Output (1-phase/3-phase)

Rated Output Capacity (1-phase/3-phase) Rated Output Current (1-phase/3-phase)

Output Rating

Carrier Frequency kHz Rated Input Current *

Constant Torque (CT)

(1-phase/3-phase) Rated Voltage/Frequency Operating Voltage Range Frequency Tolerance Short Circuit Withstand (SCCR)

Input Rating *

(A, rms symmetrical)

Weight (kg [lb]) Watt Loss 100% I (W)

Cooling Method

Braking Chopper DC Reactor EMI Filter

hp kW

kVA

* If 3-phase power source is non-symmetrical, refer to “Circuit Connections – RFI Jumper” in Chapter 2:

Installation and Wiring, page 2–14.

* Please refer to “Appendix A: Accessories” for input fusing information.

0.5/1 0.75/2 1/3 2/5 3/7.5 3/10 5/15

0.37/0.75 0.55/1.5 0.75/2.2 1.5/3.7 2.2/5.5 2.2/7.5 3.7/11

1.0/1.9 1.3/2.8 2.0/4.0 3.2/6.4 4.4/9.6 4.4/12 6.8/19

2.4/4.8 3.2/7.1 5/10 8/16 11/24 11/31 17/47

2 to 6

6.4/6.1 9.7/11 15/15 20/18.5 26/26 26/34 40/50

1-phase/3-phase 200~240 VAC (-15% to +10%), 50/60Hz

170~265 VAC

47~63 Hz

100kA

2.6 [5.7] 5.4 [11.9]

61 88 115 159 264 335 529

natural

convection

optional optional

fan

built in

GS4 230V Class Constant-Torque Specifications; Frame Sizes C~E (Model-Specific Specifications)

For Use With Three-Phase Motors Only

Model Name: GS4-xxxx 2020 2025 2030 2040 2050 2060 2075 2100

Frame Size C D E

Max Motor Output

(1-phase/3-phase)

Rated Output Capacity

(1-phase/3-phase)

Rated Output Current

(1-phase/3-phase)

Output Rating

Carrier Frequency kHz

Rated Input Current *

Constant Torque (CT)

(1-phase/3-phase) Rated Voltage/Frequency Operating Voltage Range Frequency Tolerance Short Circuit Withstand (SCCR)

Input Rating *

(A, rms symmetrical)

Weight (kg [lb]) Watt Loss 100% I (W) Cooling Method Braking Chopper DC Reactor EMI Filter

hp kW

kVA

* If 3-phase power source is non-symmetrical, refer to “Circuit Connections – RFI Jumper” in Chapter 2:

Installation and Wiring, page 2–14.

* Please refer to “Appendix A: Accessories” for input fusing information.

7.5/20 10/25 10/30 10/40 10/50 15/60 20/75 25/100

5.5/15 7.5/18.5 7.5/22 7.5/30 7.5/37 11/45 15/55 18.5/75

10/25 13/28 13/34 13/45 13/55 20/68 26/81 30/96

25/62 33/71 33/86 33/114 33/139 49/171 65/204 75/242

2 to 6

58/68 76/78 76/95 63/118 63/136 94/162 124/196 143/233

1-phase/3-phase 200~240 VAC (-15% to +10%), 50/60Hz

170~265 VAC

47~63 Hz

100kA

9.8 [21.6] 38.5 [84.9] 64.8 [143]

616 733 865 1099 1311 1518 1709 2139

fan

built in optional

optional built in

optional

Page 1–10

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 27

Chapter 1: Getting Started

230v Class – variable Torque – (model-speCifiC speCifiCaTions)

GS4 230V Class Variable-Torque Specifications (Model-Specific Specifications)

Model Name: GS4-xxxx 21P0 22P0 23P0 25P0 27P5 2010 2015 Frame Size A B

Max Motor Output

Rated Output Capacity kVA 2.0 3.2 4.4 6.8 10 13 20

Rating

Output

Input Rating *

Weight (kg [lb]) 2.6 [5.7] 5.4 [11.9] Watt Loss 100% I (W) 61 88 115 159 264 335 529

Cooling Method

Braking Chopper built in DC Reactor optional EMI Filter optional

Model Name: GS4-xxxx 2020 2025 2030 2040 2050 2060 2075 2100

Frame Size C D E

Output

Input Rating *

Weight (kg [lb]) 9.8 [21.6] 38.5 [84.9] 64.8 [143] Watt Loss 100% I (W) 616 733 865 1099 1311 1518 1709 2139 Cooling Method fan Braking Chopper built in optional DC Reactor optional built in EMI Filter optional

(VT)

Rated Output Current A 5 8 11 17 25 33 49 Carrier Frequency kHz 2 to 15

Variable Torque

Rated Input Current * A 6.4 12 16 20 28 36 52 Rated Voltage/Frequency 3-phase 200~240 VAC (-15% to +10%), 50/60Hz Operating Voltage Range 170~265 VAC Frequency Tolerance 47~63 Hz Short Circuit Withstand (SCCR)

(A, rms symmetrical)

Max Motor Output

Rated Output Capacity kVA 26 30 36 48 58 72 86 102

Rating

(VT)

Rated Output Current A 65 75 90 120 146 180 215 255

Carrier Frequency kHz 2 to 10 2 to 6

Variable Torque

Rated Input Current A 72 83 99 124 143 171 206 245 Rated Voltage/Frequency 3-phase 200~240 VAC (-15% to +10%), 50/60Hz Operating Voltage Range 170~265 VAC Frequency Tolerance 47~63 Hz Short Circuit Withstand (SCCR)

(A, rms symmetrical)

* If 3-phase power source is non-symmetrical, refer to “Circuit Connections – RFI Jumper” in Chapter 2:

Installation and Wiring, page 2–14.

* Please refer to “Appendix A: Accessories” for input fusing information.

hp 1 2 3 5 7.5 10 15 kW 0.75 1.5 2.2 3.7 5.5 7.5 11

100kA

natural

convection

hp 20 25 30 40 50 60 75 100 kW 15 18.5 22 30 37 45 55 75

fan

100kA

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 1–11

Page 28

Chapter 1: Getting Started

460v Class – ConsTanT & variable Torque – (model-speCifiC speCifiCaTions)

460V Class GS4 Specifications (Model-Specific Specifications)

Model Name: GS4-xxxx 41P0 42P0 43P0 45P0 47P5 4010 4015 4020 Frame Size A B

hp kW

Constant Torque (CT)

Output Rating

Variable Torque (VT)

CT VT

Input Rating *

Weight (kg [lb]) Watt Loss 100% I (W)

Cooling Method

Braking Chopper DC Reactor EMI Filter

Rated Voltage/Frequency Operating Voltage Range Frequency Tolerance

Short Circuit Withstand (SCCR) (A, rms symmetrical)

Max Motor Output

Rated Output Capacity kVA Rated Output Current A Carrier Frequency kHz

Max Motor Output

Rated Output Capacity kVA Rated Output Current A Carrier Frequency kHz

Rated Input Current A

* If 3-phase power source is non-symmetrical, refer to “Circuit Connections – RFI Jumper” in Chapter 2:

Installation and Wiring, page 2–14. Please refer to “Appendix A: Accessories” for input fusing information.

1 2 3 5 7.5 10 15 20

0.75 1.5 2.2 3.7 5.5 7.5 11 15

2.3 3.0 4.5 6.5 8.8 14 18 24

2.9 3.8 5.7 8.1 11 17 23 30

2 to 6

1 2 3 5 7.5 10 15 20

0.75 1.5 2.2 3.7 5.5 7.5 11 15

2.4 3.2 4.8 7.2 9.6 14 19 25

3 4 6 9 12 18 24 32

2 to 15

4.1 5.6 8.3 13 16 19 25 33

4.3 5.9 8.7 14 17 20 26 35

3-phase 380~480 VAC (-15% to +10%), 50/60Hz

323~528 VAC

47~63 Hz

100kA

2.6 [5.7] 5.4 [11.9]

59 74 104 141 180 292 380 518

natural

convection

built in

optional

fan

Page 1–12

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 29

Chapter 1: Getting Started

460V Class GS4 Specifications (Model-Specific Specifications) (continued)

Model Name: GS4-xxxx 4025 4030 4040 4050 4060 4075 4100 Frame Size C D0 D

Constant Torque (CT)

Output Rating

Variable Torque (VT)

CT VT

Input Rating *

Weight (kg [lb]) Watt Loss 100% I (W) Cooling Method Braking Chopper DC Reactor EMI Filter Model Name: GS4-xxxx 4125 4150 4175 4200 4250 4300 Frame Size E F G

Output Rating

Input Rating *

Weight (kg [lb]) 64.8 [143] 86.5 [191] 134 [295] Watt Loss 100% I (W) 2092 2599 3081 3783 4589 5772 Cooling Method fan Braking Chopper optional DC Reactor built in EMI Filter optional

Rated Voltage/Frequency Operating Voltage Range Frequency Tolerance

Short Circuit Withstand (SCCR) (A, rms symmetrical)

Constant Torque (CT)

Variable Torque (VT)

CT VT 167 207 240 300 380 400 Rated Voltage/Frequency 3-phase 380~480 VAC (-15% to +10%), 50/60Hz Operating Voltage Range Frequency Tolerance 47~63 Hz

Short Circuit Withstand (SCCR) (A, rms symmetrical)

Max Motor Output

Rated Output Capacity kVA Rated Output Current A Carrier Frequency kHz

Max Motor Output

Rated Output Capacity kVA Rated Output Current A Carrier Frequency kHz

Rated Input Current A

Max Motor Output

Rated Output Capacity kVA 136 167 197 235 280 348 Rated Output Current A 171 209 247 295 352 437 Carrier Frequency kHz 2 to 6

Max Motor Output

Rated Output Capacity kVA 143 175 207 247 295 367 Rated Output Current A 180 220 260 310 370 460 Carrier Frequency kHz 2 to 9

Rated Input Current A

hp kW

hp 125 150 175 215 250 300 kW 90 110 132 160 185 220

* If 3-phase power source is non-symmetrical, refer to “Circuit Connections – RFI Jumper” in Chapter 2:

Installation and Wiring, page 2–14. Please refer to “Appendix A: Accessories” for input fusing information.

25 30 40 50 60 75 100

18.5 22 30 37 45 55 75

29 34 45 55 69 84 114

36 43 57 69 86 105 143

2 to 6

25 30 40 50 60 75 100

18.5 22 30 37 45 55 75

30 36 48 58 73 88 120

38 45 60 73 91 110 150

2 to 10

38 45 60 70 96 108 149

40 47 63 74 101 114 157

3-phase 380~480 VAC (-15% to +10%), 50/60Hz

323~528 VAC

47~63 Hz

100kA

9.8 [21.6] 27.0 [59.5] 38.5 [84.9]

507 635 866 993 1147 1413 1742

fan

built in optional

optional built in

optional

159 197 228 285 361 380

323~528 VAC

100kA

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 1–13

Page 30

Chapter 1: Getting Started

speCifiCaTions appliCable To all gs4 models

GS4 General Specifications (Applicable to All Models)

Control Method 1: V/F (V/Hz control); 2: SVC (sensorless vector control)

Starting Torque Up to 120% (VT) or 150% (CT) for one minute

V/F Curve 4 point adjustable V/F curve and square curve

Speed Response Ability 5Hz

VT: 170% torque current CT: 180% torque current

230V series: 600.00 Hz (75hp & above: 400.00 Hz) 460V series: 600.00 Hz (125hp & above: 400.00 Hz)

Digital command: ±0.01%, -10°C to +40°C Analog command: ±0.1%, 25±10°C

Digital command: 0.01Hz Analog command: (0.03) x (max output frequency) / 60Hz [±11 bit]

VT duty: rated output current is 120% for 60 seconds CT duty: rated output current is 150% for 60 seconds

Fault restart; Parameter copy; Dwell; BACnet communication; Momentary power loss ride-through; Speed search; Over-torque detection; Torque limit; 16-step speed (max); Accel/Decel time switch; S-curve accel/decel; 3-wire sequence; Auto-Tuning (rotational, stationary); Frequency upper/lower limit settings; Cooling fan on/ off switch; Slip compensation; Torque compensation; JOG frequency; MODBUS communication (RS-485 RJ45, max 115.2 kbps); DC injection braking at start/stop; Smart stall; PID control (with sleep function); Energy saving control

230V model GS4-2020 and above: PMW control 230V model GS4-2015 and below: ON/OFF switch control 460V model GS4-4025 and above: PMW control 460V model GS4-4020 and below: ON/OFF switch control

For drive model 230V and 460V: Over-current protection for 240% rated current Current clamp: VT duty 170–175%; CT duty 180~185%

230V: drive will stop when DC-BUS voltage exceeds 410V 460V: drive will stop when DC-BUS voltage exceeds 820V

Built-in temperature sensor

Stall prevention during acceleration, deceleration, and running independently

Parameter setting up to 20 seconds

Leakage current is higher than 50% of rated current of the AC motor drive

CE, (Agency approvals do not apply to accessory conduit box kits, fan kits, flange mount kits, and braking resistors.)

Control Characteristics

Protection Characteristics

Agency Approvals

Torque Limit

Torque Accuracy ±5%

Max Output Frequency (Hz)

Output Frequency Accuracy

Output Frequency

Resolution

Overload Tolerance

Frequency Setting Signal +10V to -10V, 0 to 10V, 4~20mA, 0~20mA

Accel/Decel Time 0.00~600.00 / 0.0~6000.0 seconds

Main Control Function

Fan Control

Motor Protection Electronic thermal relay protection

Over-current Protection

Over-voltage Protection

Over-temperature

Protection

Stall Prevention

Restart After Instantaneous

Power Failure

Ground Leakage Current

Protection

, Reach, RoHS

cULus

Page 1–14

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 31

reCeiving anD insPeCtiOn

drive paCkage ConTenTs

After receiving the GS4 AC drive, please check the following:

Make sure that the package includes the dUrapUlse GS4 AC drive and the dUrapUlse GS4 AC Drive Quick-Start Guide.

Carefully follow the unpacking instructions contained in this chapter of this user manual when unpacking your dUrapUlse GS4 AC drive.

Please inspect the unit after unpacking to assure it was not damaged during shipment. Make sure that the part number printed on the package corresponds with the part number indicated on the nameplate.

Make sure that the part number indicated on the nameplate corresponds with the part number of your order.

Make sure that the voltage for the wiring lies within the range as indicated on the nameplate. Please install the GS4 AC drive according to this manual.

Before applying the power, please make sure that all the devices, including power, motor, control board, and digital keypad are connected correctly.

When wiring the GS4 AC drive, please make sure that the wiring of input terminals “R/L1, S/L2, T/L3” and output terminals “U/T1, V/T2, W/T3” are correct to prevent drive damage.

When power is applied, select the language and set parameter groups via the digital keypad (GS4-KPD). When executing a trial run, please begin with a low speed, and then gradually increase the speed until the desired speed is reached.

The GS4 AC drive should be kept in the shipping carton or crate before installation. In order to retain the warranty coverage, the GS4 AC drive should be stored properly when it is not to be used for an extended period of time. Refer to the preceding “Environmental Information” section for proper storage conditions.

Chapter 1: Getting Started

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 1–15

Page 32

Chapter 1: Getting Started

GS4- 4 7P5

Series Name

MODel nUMber exPlanatiOn

Applicable Motor Capacity*

1P0: 1.0hp 2P0: 2.0hp 3P0: 3.0hp 5P0: 5.0hp 7P5: 7.5hp 010: 10hp 015: 15hp 020: 20hp 025: 25hp 030: 30hp 040: 40hp 050: 50hp 060: 60hp 075: 75hp 100: 100hp 125: 125hp 150: 150hp 175: 175hp 200: 200hp 250: 250hp 300: 300hp *Not all capacities are available in each voltage.

Input Voltage

2: 230VAC 4: 460VAC

naMePlate infOrMatiOn

MODEL : GS4-21P0 INPUT : (Variable Torque / Constant Torque)

VT : 3PH 200-240V 50/60Hz 6.4A CT : 3PH 200-240V 50/60Hz 6.1A CT : 1PH 200-240V 50/60Hz 6.4A OUTPUT : (Variable Torque / Constant Torque) VT : 3PH 0-240V 5A 2.0KVA 0.75KW/1HP CT : 3PH 0-240V 4.8A 1.9KVA 0.75KW/1HP CT : 3PH 0-240V 2.4A 1.0KVA 0.37KW/0.5HP

FREQUENCY RANGE : 0-600Hz SHORT CIRCUIT CURRENT : 100KA

IP20 / UL Open-Type with top cover removed (rated -10°C to 50°C Ambient). IP20 / NEMA 1 / UL Type 1 with top cover Installed (rated -10°C to 40°C Ambient). Refer to user manual.

MODEL : GS4-41P0 INPUT : (Variable Torque / Constant Torque)

VT : 3PH 380-480V 50/60Hz 4.3A CT : 3PH 380-480V 50/60Hz 4.1A OUTPUT : (Variable Torque / Constant Torque) VT : 3PH 0-480V 3.0A 2.4KVA 0.75KW/1HP CT : 3PH 0-480V 2.9A 2.3KVA 0.75KW/1HP

FREQUENCY RANGE : 0-600Hz SHORT CIRCUIT CURRENT : 100KA

IP20 / UL Open-Type with top cover removed (rated -10°C to 50°C Ambient). IP20 / NEMA 1 / UL Type 1 with top cover Installed (rated -10°C to 40°C Ambient). Refer to user manual.

GS4-21P0+W15170017

Automationdirect.com

Ver : 01.00 MADE IN CHINA

GS4-41P0+W15150001

Automationdirect.com

Ver : 01.00 MADE IN CHINA

Page 1–16

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 33

UnPaCking YOUr gs4 durapulse aC Drive

CAUTION: The larger GS4 DURApUlse AC drives, frame sizes D through G, can easily be permanently damaged during unpacking, unless the following instructions are followed carefully.

lifTing eye loCaTions and insTruCTions

GS4 DURApUlse AC drives frame sizes D(0) through G have lifting eyes built in to the four corners of the backplane, as shown in this typical drawing.

Chapter 1: Getting Started

Frames D through E: Ensure that the lifting hook properly

goes through the lifting eyes, as shown.

Frames F through G: Ensure that the lifting hook properly

goes through the lifting eyes, as shown.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 1–17

Page 34

Chapter 1: Getting Started

Frames D(0) through E: Ensure that the angle between the

lifting eyes and the lifting device is within the specification, as shown.

Frames F through G: Ensure that the angle between

the lifting eyes and the lifting device is within the specification, as shown. Use a spreader bar to avoid bending the lifting eyes.

Page 1–18

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 35

unpaCking The drive

unpaCking frame size d(0) drives

Remove the 12 cover screws to open the crate.

Remove the packing filler and Quick-Start Guide.

Chapter 1: Getting Started

Remove the 8 screws that are fastened on the pallet, and remove the wooden plate.

Lift the drive by hooking the lifting eyes. The drive is now ready for installation.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 1–19

Page 36

Chapter 1: Getting Started

unpaCking frame size e drives

Remove the 4 screws on the iron plates. There are 4 iron plates and a total of 16 screws.

Remove the crate cover, packing filler, and Quick-Start Guide.

Remove the 8 screws that hold the drive to the pallet.

Lift the drive by hooking the lifting eyes. The drive is now ready for installation.

Page 1–20

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 37

unpaCking frame size f drives

Remove the 6 clips on the side of the crate with a flat-head screwdriver.

Remove the crate cover, packing filler, and Quick-Start Guide.

Chapter 1: Getting Started

Remove the 5 screws that hold the drive to the pallet.

Use a spreader bar to avoid bending the lifting eyes, and lift the drive by hooking the lifting eyes. The drive is now ready for installation.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 1–21

Page 38

Chapter 1: Getting Started

unpaCking frame size g drives

Remove the 6 clips on the side of the crate with a flat-head screwdriver.

Remove the crate cover, packing filler, and Quick-Start Guide.

Remove the 5 screws that hold the drive to the pallet.

Use a spreader bar to avoid bending the lifting eyes, and lift the drive by hooking the lifting eyes. The drive is now ready for installation.

Page 1–22

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 39

Chapter

InstallatIon and WIrIng

able of ConTenTs

Drive Models by Frame Size � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–2

Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–2

Minimum Clearances and Air Flow� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–3

Minimum Clearance Distances � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–3 Airflow and Power Dissipation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–6

Dimensions� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–7

Circuit Connections – RFI Jumper � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–14

RFI Jumper Removal� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–14 Isolating Main Power from Ground � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–15 Floating Ground System (IT Systems) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–16 Asymmetric Ground System (Corner Grounded TN Systems) � � � � � � � � � � � � � � � � � � � � � � �2–16

Circuit Connections – Warnings and Notes � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–17

Danger!� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–17

Wiring Terminal Access � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–20

Control Terminal Access� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–20 Removing the Control Terminal Block � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–21

Main Circuit Wiring Terminals � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–22

Main Terminal Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–22 Wiring Terminal Connector Dimensions – Main-Circuit Terminals � � � � � � � � � � � � � � � � � � � � �2–24 Main Terminal Diagrams � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–28

Main Circuit Wiring Diagrams � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–30

Control Circuit Wiring Terminals � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–32

Control Terminal Specifications� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–32 Control Terminal Block Diagram & Wiring Specifications � � � � � � � � � � � � � � � � � � � � � � � � � 2–34 Control Terminal Wiring Instructions� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–34

Control Circuit Wiring Diagrams � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–35

Digital Inputs� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–35 Full I/O with Sinking Inputs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–36 Full I/O with Sourcing Inputs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2–37

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Page 40

Chapter 2: Installation and Wiring

Drive MODels bY fraMe size

GS4 DURApUlse Drive Models by Frame Size

Frame Drive

B C D0 D E F G

GS4-21P0; GS4-41P0; GS4-22P0; GS4-42P0; GS4-23P0; GS4-43P0; GS4-25P0; GS4-45P0; GS4-47P5

GS4-27P5; GS4-2010; GS4-4010; GS4-2015; GS4-4015; GS4-4020 GS4-2020; GS4-2025; GS4-4025; GS4-2030; GS4-4030; GS4-4040 GS4-4050; GS4-4060 GS4-2040; GS4-2050; GS4-4075; GS4-4100 GS4-2060; GS4-2075; GS4-2100; GS4-4125; GS4-4150 GS4-4175; GS4-4200 GS4-4250; GS4-4300

installatiOn

Install the AC drive in an enclosure that is specifically designed to house electrical and electronic control equipment. Provide proper spacing within the enclosure to allow the dissipation of heat produced by the drive and any other included electrical and electronic equipment. Ventilation or air conditioning may also be required, depending upon the application.

fAIluRe to obseRve these pRecAutIoNs mAy dAmAGe the dRIve ANd voId the WARRANty!

Improper installation of the AC drive will greatly reduce its life. Observe the following precautions when installing the drive:

•

Do not mount the AC drive near heat-radiating elements or in direct sunlight�

•

Do not install the AC drive in a place subjected to high temperature, high humidity, excessive vibration, corrosive gases or liquids, or airborne dust or metallic particles�

•

Install the AC drive in Pollution Degree 2 environments only� Pollution Degree 2: Normally only non-conductive pollution occurs� Temporary conductivity caused by condensation is to be expected�

•

Install the AC drive in a metal cabinet� When installing one drive below another, use a metal separator between the drives to prevent mutual heating and to prevent the risk of fire�

•

Mount the AC drive securely on a flat, rigid, non-flammable surface�

•

Mount the AC drive vertically and do not restrict the air flow to the heat sink fins�

•

Prevent fiber particles, scraps of paper, shredded wood saw dust, metal particles, etc� from adhering to the heat sink�

Ac dRIves GeNeRAte A lARGe AmouNt of heAt WhIch mAy dAmAGe them. AuxIlIARy coolING methods

ARe typIcAlly RequIRed IN oRdeR Not to exceed mAxImum AmbIeNt tempeRAtuRes.

Page 2–2

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 41

MiniMUM ClearanCes anD air flOw

diagram direCTional arroWs

•

Air Inflow: Blue Arrow → →

•

Air Outflow: Red Arrow → →

•

Distance: Black Arrows ↔ ↔

minimum ClearanCe disTanCes

1) single drive insTallaTion (frames a–g)

Chapter 2: Installation and Wiring

2) mulTiple drives side-by-side (frames a–C)

3) mulTiple drives side-by-side (frames d0, d, e, f)

•

Install a metal separator between the drives�

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Page 42

Chapter 2: Installation and Wiring

4) mulTiple drives side-by-side (frame g)

5) mulTiple drives side-by-side and over/under (frames a–g)

•

When installing one AC motor drive below another one (over/under installation), use a metal separator between the drives to prevent mutual heating�

•

The temperature measured at the fan’s inflow side must be lower than the temperature measured at the operation side�

•

If the fan’s inflow temperature is higher, use a larger metal separator�

•

Ta = ambient air temperature measured at 50mm away from the fan’s inflow side�

Dimensions for Minimum Clearance Figures 1–5 * Frame Size A (mm / in) B (mm / in) C (mm / in) D (mm / in) A–C D(0)–F G

60 / 2�4 30 / 1�2 10 / 0�4 0 / 0 100 / 4�0 50 / 2�0 n/a 0 / 0 200 / 7�9 100 / 4�0 n/a 0 / 0

* The minimum mounting clearances stated in this table applies to GS4 drives frames A to G. Failure to follow the minimum mounting clearances may cause the fan to malfunction and cause a heat dissipation problem.

Page 2–4

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Chapter 2: Installation and Wiring

•

Mounting clearances stated in the figure are for installing the drive in an open area� To install the drive in a confined space (such as cabinet or electric box), please observe these three rules: (1) Maintain the minimum mounting clearances� (2) Install ambient air ventilation equipment or an air conditioner to keep surrounding temperature lower than operation temperature� (3) Refer to parameter setting and set up P2�10 Carrier Frequency, P6�00/P6�02 Electronic Thermal Overload Relay, P6�33 Method of Derating, and P6�34 VT/CT Duty Selection�

•

The following table shows the heat dissipation and the required air volume when installing a single drive in a confined space� When installing multiple drives, the required air volume should be multiplied by the number of drives�

•

Refer to the following chart (Air flow rate for cooling) for ventilation equipment design and selection�

•

Refer to the following chart (Power dissipation) for air conditioner design and selection�

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Chapter 2: Installation and Wiring

airfloW and poWer dissipaTion

Airflow Rate1) for Cooling Power Dissipation

Model Number

GS4-21P0 – – – – – – 33 27 60 GS4-22P0 14 – 14 24 – 24 56 31 87 GS4-23P0 14 – 14 24 – 24 79 36 115 GS4-25P0 10 – 10 17 – 17 113 46 159 GS4-27P5 40 14 54 68 24 92 197 67 264 GS4-2010 66 14 80 112 24 136 249 86 335 GS4-2015 58 14 73 99 24 123 409 121 530 GS4-2020 166 12 178 282 20 302 455 161 616 GS4-2025 166 12 178 282 20 302 549 184 733 GS4-2030 166 12 178 282 20 302 649 216 865 GS4-2040 179 30 209 304 51 355 913 186 1099 GS4-2050 179 30 209 304 51 355 1091 220 1311 GS4-2060 228 73 301 387 124 511 1251 267 1518 GS4-2075 228 73 301 387 124 511 1401 308 1709 GS4-2100 246 73 319 418 124 542 1770 369 2139 GS4-41P0 – – – – – – 33 25 58 GS4-42P0 – – – – – – 45 29 74 GS4-43P0 14 – 14 24 – 24 71 33 104 GS4-45P0 10 – 10 17 – 17 103 38 141 GS4-47P5 10 – 10 17 – 17 134 46 180 GS4-4010 40 14 54 68 24 92 216 76 292 GS4-4015 66 14 80 112 24 136 287 93 380 GS4-4020 58 14 73 99 24 123 396 122 518 GS4-4025 99 21 120 168 36 204 369 138 507 GS4-4030 99 21 120 168 36 204 476 158 634 GS4-4040 126 21 147 214 36 250 655 211 866 GS4-4050 179 30 209 304 51 355 809 184 993 GS4-4060 179 30 209 304 51 355 929 218 1147 GS4-4075 179 30 209 304 51 355 1156 257 1413 GS4-4100 186 30 216 316 51 367 1408 334 1742 GS4-4125 257 73 330 437 124 561 1693 399 2092 GS4-4150 223 73 296 379 124 503 2107 491 2598 GS4-4175 224 112 336 381 190 571 2502 579 3081 GS4-4200 289 112 401 491 190 681 3096 687 3783 GS4-4250 GS4-4300 454 771 5772

• The required airflow shown in chart is for installing a single GS4 drive in a confined space�

• When installing multiple GS4 drives, the required air volume would be the required air volume for a single GS4 drive multiplied by the number of GS4 drives�

1) External flow rate is across the heat sink.

Internal flow rate is through the chassis. Published flow rates are the result of active cooling using fans; factory-installed in the drive. Unpublished flow rates (-) are the result of passive cooling in drives without factory-installed fans.

2) When calculating power dissipation (Watt Loss) use the total value if the drive is foot mounted,

or the internal value if the drive is flange mounted. Where only a total value is published, these models cannot be flange mounted.

Flow Rate1) (cfm) Flow Rate1) (m3/hr) Power Dissipation (Watt)

External Internal Total External Internal Total

–

454

Loss

External

(Heat sink)

–

771

• Heat dissipation shown in the chart is for installing a single GS4 drive in a confined space�

• When installing multiple drives, the volume of heat dissipation should be the heat dissipated by a single GS4 drive multiplied by the number of GS4 drives�

• Heat dissipation for each model is calculated by rated voltage, current and default carrier frequency�

Internal Total

–

4589

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Page 45

DiMensiOns

(Units = mm [in])

See our website: www.AutomationDirect.com for complete engineering drawings.

Chapter 2: Installation and Wiring

GS4 durapulse Frame Sizes by Drive Model

230V 460V

Drive Frame Drive Frame GS4-21P0 GS4-22P0 GS4-42P0 GS4-23P0 GS4-43P0 GS4-25P0 GS4-45P0 GS4-27P5 GS4-2010 GS4-4010

GS4-2020 GS4-2025 GS4-4025

GS4-2040 GS4-2050 GS4-4050 GS4-2060 GS4-2075 GS4-4075 GS4-2100 GS4-4100

GS4-41P0

GS4-47P5

GS4-4020

GS4-4040

GS4-4060

GS4-4125 GS4-4150 GS4-4175 GS4-4200 GS4-4250 GS4-4300

BGS4-2015 GS4-4015

CGS4-2030 GS4-4030

frame size a

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Page 46

Chapter 2: Installation and Wiring

dimensions (Units = mm [in])

See our website: www.AutomationDirect.com for complete engineering drawings.

frame size b

frame size C

Ø34.0 [1.34]

Page 2–8

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Chapter 2: Installation and Wiring

dimensions (Units = mm [in])

See our website: www.AutomationDirect.com for complete engineering drawings.

frame size d0

frame size d0 WiTh ConduiT box

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Page 48

Chapter 2: Installation and Wiring

dimensions (Units = mm [in])

See our website: www.AutomationDirect.com for complete engineering drawings.

frame size d

frame size d WiTh ConduiT box

Page 2–10

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Chapter 2: Installation and Wiring

dimensions (Units = mm [in])

See our website: www.AutomationDirect.com for complete engineering drawings.

frame size e

frame size e WiTh ConduiT box

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Page 50

Chapter 2: Installation and Wiring

dimensions (Units = mm [in])

See our website: www.AutomationDirect.com for complete engineering drawings.

frame size f

frame size f WiTh ConduiT box

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DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Chapter 2: Installation and Wiring

dimensions (Units = mm [in])

See our website: www.AutomationDirect.com for complete engineering drawings.

frame size g (noT Capable of flange moUnTing)

frame size g WiTh ConduiT box (noT Capable of flange moUnTing)

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Chapter 2: Installation and Wiring

CirCUit COnneCtiOns – rfi JUMPer

RFI Jumper: The GS4 drive may emit electrical noise. The RFI jumper, when left in place, enables an internal filter to supress radio frequency interference on the power line.

rfi jumper removal

The RFI jumper may need to be removed in some cases, such as situations in which the GS4 drive is powered from an Asymmetric Ground System (Corner Grounded TN System), as described on

page 2–16.

frames a~C

Screw Torque: 8~10 kg·cm [6.9~8.7 lb·in] Loosen the screw indicated in the view below, and remove the RFI jumper. Tighten the screw to

the specified torque after the RFI jumper is removed.

frames d0~g

Remove the MOV-PLATE by hand; no screws need to be loosened.

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Chapter 2: Installation and Wiring

Ground terminals

isolaTing main poWer from ground

WARNING: If the poWeR dIstRIbutIoN system supplyING the Gs4 dRIve Is sINGle phAse, the RfI

jumpeR must be Removed.

WARNING: If the poWeR dIstRIbutIoN system supplyING the Gs4 dRIve Is A floAtING-GRouNd system (It) oR AN AsymmetRIc-GRouNd system (tN), the RfI jumpeR must be Removed.

If the power distribution system supplying the GS4 drive is a floating ground system (IT) or an asymmetric ground system (TN), the RFI jumper must be removed. Removing the RFI jumper disconnects the internal RFI filter capacitor between the drive’s frame and circuits to avoid damaging those circuits and to reduce ground leakage current.

Important points regarding ground connection

•

To ensure the safety of personnel, proper operation, and to reduce electromagnetic radiation, the GS4 drive must be properly grounded during installation�

•

The diameter of the cables must meet the size specified by applicable codes and regulations�

•

The grounding cable must be connected to the ground of the GS4 drive to meet safety regulations�

•

The grounding cable can be used as the ground for equipment only when the aforementioned points are met�

•

When installing multiple GS4 drives, do not connect the grounds of the AC motor drive in series� Instead, utilize a single-point grounding scheme (as shown below), or provide individual grounding rods for each GS4 drive�

Best wiring setup for ground wires

Pay particular attention to the following WARNINGS:

WARNING: do Not Remove the RfI jumpeR WhIle poWeR Is ApplIed to the Gs4 dRIve.

WARNING: cuttING the RfI shoRt-cIRcuIt cAble WIll Also cut off the coNductIvIty of the

cApAcItoR. GAp dIschARGe mAy occuR oNce the tRANsIeNt voltAGe exceeds 1000v.

WARNING: the RfI jumpeR mAy Not be Removed If the mAIN poWeR Is A GRouNded poWeR system.

WARNING: the RfI jumpeR mAy Not be Removed WhIle coNductING hIGh voltAGe tests.

WARNING: WheN coNductING A hIGh voltAGe test to the eNtIRe fAcIlIty, the mAIN poWeR ANd the

motoR must be dIscoNNected If leAkAGe cuRReNt Is too hIGh.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Page 54

Chapter 2: Installation and Wiring

floaTing ground sysTem (iT sysTems)

A floating ground system is also called an IT system, an ungrounded system, or a high impedance/ resistance grounding system (greater than 30Ω).

cAutIoN: do Not INstAll AN exteRNAl RfI/emc fIlteR! the emc fIlteR WIll pAss thRouGh

the RfI cApAcItoR, thus coNNectING poWeR INput to GRouNd. thIs Is veRy dANGeRous ANd cAN eAsIly dAmAGe the Gs4 dRIve.

asymmeTriC ground sysTem (Corner grounded Tn sysTems)

cAutIoN: do Not Remove the RfI jumpeR WhIle the INput teRmINAls of the Gs4 dRIve

cARRIes poWeR.

The RFI jumper must be removed in the following four situations. This is to prevent the system from grounding through the RFI capacitor, damaging the GS4 drive.

RFI Jumper Must Be Removed (Asymmetric Ground / Corner Grounded TN Systems)

1) Grounding at a Corner of a Triangle Configuration 2) Grounding at a Midpoint in a Polygonal Configuration

3) Grounding at One End in a Single-Phase Configuration

4) No Stable Neutral Grounding in a Three-Phase Autotransformer Configuration

The RFI jumper should be left in place for a symmetrically grounded system.

RFI Jumper Left In Place (Symmetrical Ground System)

Internal grounding through internal RFI filter, which reduces electromagnetic radiation.

In a situation with higher requirements for electromagnetic compatibility, and using a symmetrical grounding power system, an EMC filter can be installed.

As a reference, the diagram on the right is a symmetrical grounding power system.

Page 2–16

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 55

CirCUit COnneCtiOns – warnings anD nOtes

Danger!

hAzARdous voltAGe! befoRe mAkING ANy coNNectIoN to the Ac dRIve, dIscoNNect All poWeR to the Ac dRIve, ANd WAIt fIve mINutes foR dc bus cApAcItoRs to dIschARGe.

WARNING: ANy electRIcAl oR mechANIcAl modIfIcAtIoN to thIs equIpmeNt WIll voId All WARRANtIes,

mAy Result IN A sAfety hAzARd, ANd mAy voId the ul lIstING.

WARNING: do Not coNNect the Ac INput poWeR to the t1, t2, ANd t3 output teRmINAls. doING thIs

WIll dAmAGe the Ac dRIve.

WARNING: do Not coNNect sINGle-phAse poWeR to A thRee-phAse dRIve model.

WARNING: tIGhteN All scReWs to the pRopeR toRque RAtING. see “mAIN cIRcuIt WIRING” lAteR IN thIs

chApteR.

Wiring noTes: please read prior To insTallaTion.

During installation, follow all local electrical, construction, and safety codes for the country in which the AC drive is to be installed�

Refer to the “dUrapUlse GS4 AC Drive Specifications” in chapter 1 for voltage and current requirements�

Torque the screws of the main circuit terminals to prevent loosening due to vibration�

The addition of a magnetic contactor (MC) in the AC line power input wiring is recommended to turn off power quickly and reduce the possibility of malfunction if the protection function of the GS4 AC drive is activated� Both ends of the MC should have an R-C surge absorber�

Do not use a power circuit contactor or disconnect switch for normal run/stop control of the GS4 AC drive and motor� This will reduce the operating life cycle of the AC drive� Cycling a power circuit switching device while the AC drive is in run mode should be done only in emergency situations�

Make sure the appropriate protective devices (circuit breaker or fuses) are connected between the power supply and AC drive�

Make sure that the leads are connected correctly and that the GS4 AC drive is properly

grounded. (Ground resistance should not exceed 0.1Ω.)

Use ground leads that comply with AWG/MCM standards and keep them as short as possible�

Multiple GS4 AC drives can be installed in one location� All of the units should be grounded directly to a common ground terminal� The GS4 AC drive ground terminals may also be connected in parallel, as shown in the figure below� Make sure there are no ground loops�

Chapter 2: Installation and Wiring

Correct Incorrect

10)

When the GS4 AC drive output terminals T1, T2, and T3 are connected to the motor terminals T1, T2, and T3, respectively, the motor will rotate counterclockwise (as viewed from the shaft end of the motor) when a forward operation command is received� To reverse the direction of motor rotation, switch the connections of any of the two motor leads�

11)

Make sure that the power source is capable of supplying the correct voltage and required current to the GS4 AC drive�

12)

Do not attach or remove wiring when power is applied to the GS4 AC drive�

13)

Do not inspect components unless inside “POWER” lamp is turned off�

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Forward Running

Page 2–17

Page 56

Chapter 2: Installation and Wiring

14)

Do not monitor the signals on the circuit board while the GS4 AC drive is in operation�

15)

GS4 series AC drives cannot be used with single-phase motors�

16)

Route the power and control wires separately, or at 90 degree angle to each other�

17)

Ground both ends of the shield wire or conduit for the power wiring� a) If using a “VFD cable,” follow the manufacturer’s recommendation for grounding the cable shield� b) If using conduit, bond and ground conduit according to applicable electrical codes�

18)

If a filter is required for reducing EMI (Electro Magnetic Interference), install it as close as possible to the GS4 AC drive� EMI can also be reduced by lowering the Carrier Frequency� Please refer to the “Applied EMI/RFI Techniques” white paper at support�automationdirect�com�

19)

If the GS4 AC drive is installed in a place where a load reactor is needed, install the reactor close to the T1, T2, and T3 side of GS4 AC drive� Do not use a Capacitor, L-C Filter (InductanceCapacitance), or R-C Filter (Resistance-Capacitance)�

20)

When using a GFCI (Ground Fault Circuit Interrupt), select current sensor with sensitivity of 200mA or higher, and not less than 0�1-second operation time to avoid nuisance tripping�

main poWer Terminals

•

Do not supply GS4 460VAC models with single-phase power� R/L1, S/L2, and T/L3 have no phase-sequence requirement; they can be wired in any order�

•

Do NOT start/stop the GS4 AC drive by turning input power ON/OFF� Start/stop the GS4 AC drive using RUN/STOP commands via control terminals or the keypad� If you must start/stop the GS4 AC drive by turning power ON/OFF, it is recommended to do so only ONCE per hour�

ouTpuT Terminals for main CirCuiT

•

Do not connect phase-compensation, L-C (Inductance-Capacitance) , or R-C (Resistance Capacitance) capacitors to the output terminals U/T1, V/T2, W/T3 of the GS4 AC drive�

•

DO NOT connect phase-compensation capacitors or surge absorbers to the output terminals of the GS4 AC drive�

•

Use a well-insulated motor suitable for inverter operation�

Page 2–18

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Chapter 2: Installation and Wiring

Terminals for ConneCTing dC reaCTor, exTernal brake resisTor, exTernal brake resisTor and dC CirCuiT

•

Terminals +1 and +2 are used to connect an optional DC reactor to improve the power factor� For the factory setting, they are connected by a short-circuit jumper� Remove this jumper before connecting a DC reactor�

•

When the GS4 AC Drive is connected directly to a large-capacity power transformer (600kVA or above) or when a phase lead capacitor is switched, excess peak currents may occur in the power input circuit due to the load changes� The converter section may be damaged� To avoid this damage, it is recommend to use a serial connected AC input reactor at the GS4 AC Drive mains input side to reduce the current and improve the input power efficiency�

•

Connect an optional brake resistor or brake unit in applications with frequent deceleration ramps, short deceleration time, too low brake torque or requiring increased brake torque�

•

For GS4 frame sizes A–C, the external brake resistor should be connected to the terminals (B1, B2) of GS4 drives�

•

For the models without built-in braking chopper, connect external brake unit and brake resistor (both of them are optional) to increase brake torque�

•

If the terminals [+1], [+2], and [-] are not used, leave these three terminals open�

•

DO NOT connect [+1, -], [+2, -], [+1/DC+, -/DC-], or brake resistor directly to prevent drive damage�

•

DC+ and DC- are connected for common DC bus, please refer to “Main Circuit Wiring Terminals” in this chapter for wiring terminal specification and wire gauge information�

•

Please refer to the dUrapUlse Drives Dynamic Braking User Manual for more information on installing brake units� (Available for free download at http://www�automationdirect�com/static/manuals/index�html�)

moTor operaTion preCauTions

When using the GS4 AC drive to operate a standard 3-phase induction motor, notice that the energy loss is greater than for an inverter duty motor�

Avoid running a standard induction motor at low speed, which may cause the motor temperature to exceed the motor rating due to limited airflow produced by the motor’s fan�

When the standard motor operates at low speed, the output load must be decreased�

If 100% output torque is desired at low speed, it may be necessary to use a special “inverter-duty” rated motor�

shorT CirCuiT WiThsTand (sCCr)

All DURApUlse GS4 series drives are suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical amperes.

The maximum voltage is 240V for all 230V models, and 480V for all 460V models.

appliCable Codes

All DURApUlse

GS4

AC drives are Underwriters Laboratories, Inc. (UL) and Canadian Underwriters Laboratories (cUL) listed, and therefore comply with the requirements of the National Electrical Code (NEC) and the Canadian Electrical Code (CEC).

Installations intended to meet the UL and cUL requirements must follow the instructions provided in “Wiring Notes” as a minimum standard. Follow all local codes that exceed UL and cUL requirements. Refer to the technical data label affixed to the AC drive and the motor nameplate for electrical data.

The “Circuit Protection Devices” section in Appendix A lists the recommended fuse part number for each DURApUlse part number. These fuses (or equivalent) must be used on all installations where compliance with U.L. standards is required.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 2–19

Page 58

Chapter 2: Installation and Wiring

wiring terMinal aCCess

ConTrol Terminal aCCess

Remove the drive front cover to access and wire the multi-function input/output control terminals.

drive frames a and b

Loosen the captive screw and press the tabs on both sides to remove the cover.

drive frames C and d

Loosen the captive screws and press the tabs on both sides to remove the cover.

Page 2–20

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 59

Chapter 2: Installation and Wiring

ConTrol Terminal aCCess (ConTinued)

drive frame e, f, and g

Loosen the captive screws, lift the cover slightly, and pull it outward. (Frame E shown)

removing The ConTrol Terminal bloCk

The control terminal block is removable for ease of wiring.

Loosen the captive screws�

Slide the control board toward the bottom of the drive to disconnect the pins (1)�

Lift the control board straight out (2)�

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 2–21

Page 60

Chapter 2: Installation and Wiring

Main CirCUit wiring terMinals

main Terminal speCifiCaTions

Main Circuit Terminals

Terminal Description R/L1 S/L2 T/L3 U/T1, V/T2, W/T3 +1, +2 B1, B2 +1/DC+, -/DC-

Main Circuit Wiring Specifications

AC Drive Frame Size

* Wiring specifications for drives with optional conduit box

AC Drive Model

GS4-21P0 GS4-22P0 GS4-23P0 GS4-25P0 GS4-41P0 GS4-42P0 GS4-43P0 GS4-45P0 GS4-47P5 GS4-27P5 GS4-2010 GS4-2015 GS4-4010 GS4-4015 GS4-4020 GS4-2020 GS4-2025 GS4-2030 GS4-4025 GS4-4030 GS4-4040 GS4-4050

GS4-4060

GS4-2040

GS4-2050

GS4-4075

GS4-4100

GS4-2060

GS4-2075

GS4-2100

GS4-4125

GS4-4150

1/0 [53�5]

2/0 [67�4]

300 MCM [152]

4/0 [107]*

300 MCM x2 [152 x2]

4/0 x2 [107 x2]*

Input Power – phase 1 Input Power – phase 2 Input Power – phase 3 AC Drive Output DC Choke Connection (frames A–C) Braking Resistor Connection (frames A–C) External Dynamic Brake Unit (frames D–G)

Ground

Wire Range

(AWG [mm2])

Max Min

14 [2�1] 12 [3�3] 10 [5�3]

8 [8�4]

14 [2�1]

10 [5�3]

8 [8�4]

6 [13�3]

4 [21�2]

8 [8�4]

6 [13�3] 1 [42�4]

1/0 [53�5]

4 [21�2]

2 [33�6] 1/0 [53�5] 2/0 [67�4]

1/0 [53�5]*

4/0 [107]

3/0 [85]*

250 MCM [127]

4/0 [107]*

3/0 [85]

2/0 [67�4]*

300 MCM [152]

4/0 [107]*

1/0 x2 [53�5 x2]

3/0 x2 [85 x2]

2/0 x2 [67�4 x2]*

4/0 x2 [107 x2] 3/0 x2 [85 x2]*

1/0 x2 [53�5 x2]

3/0 x2 [85 x2]

2/0 x2 [67�4 x2]*

(continued next page)

Terminal

Tightening

Torque

(kg·cm [lb·in])

20 [17�4]

35 [30�4]

80 [69�4]

81�6 [70�8]

200 [173]

Page 2–22

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 61

Chapter 2: Installation and Wiring

Main Circuit Wiring Specifications (continued) AC Drive Frame Size

AC Drive Model

GS4-4175

GS4-4200

GS4-4250

GS4-4300

GS4-4250

GS4-4300

Max Min

300 MCM x2 [152 x2]

4/0 x2 [107 x2]*

Terminals R/L11,12; S/L21,22; T/L31,32

300 MCM x4 [152 x4]

Terminals U/T1, V/T2, W/T3, +1/DC+, -/DC-

500 MCM x2 [253 x2]

* Wiring specifications for drives with optional conduit box

UL installations must use 600V, 75°C or 90°C wires. Use copper wire only.

Wire Range

(AWG [mm2])

(kg·cm [lb·in])

4/0 x2 [107 x2] 3/0 x2 [85 x2]*

4/0 x2 [107 x2]

2/0 x4 [67�4 x4]

1/0 x4 [53�5 x4]*

3/0 x4 [85 x4]

2/0 x4 [67�4 x4]*

400 MCM x2 [203 x2]

300 MCM x2 [152 x2]*

500 MCM x2 [253 x2]

400 MCM x2 [203 x2]*

Terminal

Tightening

Torque

200 [173]

400 [354]

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 2–23

Page 62

Chapter 2: Installation and Wiring

Wiring Terminal ConneCTor dimensions – main-CirCuiT Terminals

dimensions = mm

frame size a (gs4 model #s: 21p0, 22p0, 23p0, 25p0, 41p0, 42p0, 43p0, 45p0, 47p5)

NOTE: Crimp connectors are NOT required on A, B, and C frame drives. NOTE: Heat shrink should comply with UL (600V, YDPU2).

Power Terminal Wiring Connectors: Heat Shrink Tubing:

frame size b (gs4 model #s: 27p5, 2010, 2015, 4010, 4015, 4020)

NOTE: Crimp connectors are NOT required on A, B, and C frame drives. NOTE: Heat shrink should comply with UL (600V, YDPU2).

Power Terminal Wiring Connectors: Heat Shrink Tubing:

Page 2–24

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 63

Chapter 2: Installation and Wiring

main CirCuiT Crimp ConneCTor speCifiCaTions (ConTinued)

dimensions = mm

frame size C (gs4 model #s: 2020, 2025, 2030, 4025, 4030, 4040)

NOTE: Crimp connectors are NOT required on A, B, and C frame drives. NOTE: Heat shrink should comply with UL (600V, YDPU2).

Power Terminal Wiring Connectors: Heat Shrink Tubing:

frame size d0 (gs4 model #s: 4050, 4060)

NOTE: Crimp connectors ARE required on D0, D, E, F, and G frame drives. NOTE: Heat shrink should comply with UL (600V, YDPU2).

Power Terminal Wiring Connectors: (except Ground Terminal Connectors)

-2

8.2 Min.

Ring lug

Heat Shrink Tubing: (non-ground power connectors)

13 Min.

Heat Shrink Tube

WIRE

GROUND Terminal Wiring Connectors ONLY:

22 Max.

8.2 Min.

11 Max.

Heat Shrink Tubing: (ground terminal power connectors)

Ring lug

13 Min.

32 Max.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Heat Shrink Tube

WIRE

Page 2–25

Page 64

Chapter 2: Installation and Wiring

main CirCuiT Crimp ConneCTor speCifiCaTions (ConTinued)

dimensions = mm

frame size d (gs4 model #s: 2040, 2050, 4075, 4100)

NOTE: Crimp connectors ARE required on D0, D, E, F, and G frame drives. NOTE: ADC ring terminal part #s for GS4 A-frame drives:

V70RK004011, V70RK004012, V70RK004017, V70RK004018

NOTE: Heat shrink should comply with UL (600V, YDPU2).

Power Terminal Wiring Connectors: Heat Shrink Tubing:

frame size e (gs4 model #s: 2060, 2075, 2100, 4125, 4150)

NOTE: Crimp connectors ARE required on D0, D, E, F, and G frame drives. NOTE: Heat shrink should comply with UL (600V, YDPU2).

Power Terminal Wiring Connectors: (except Ground Terminal Connectors)

-4

70MAX.

GROUND Terminal Wiring Connectors ONLY:

17.0MAX.

31MAX.

8.2MIN.

26.5MAX.

28.0MAX.

Heat Shrink Tubing:

Page 2–26

8.2MIN.

65.0MAX

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 65

Chapter 2: Installation and Wiring

main CirCuiT Crimp ConneCTor speCifiCaTions (ConTinued)

dimensions = mm

frame size f (gs4 model #s: 4175, 4200)

NOTE: Crimp connectors ARE required on D0, D, E, F, and G frame drives. NOTE: Heat shrink should comply with UL (600V, YDPU2).

Power Terminal Wiring Connectors: Heat Shrink Tubing:

-4

70MAX.

frame size g (gs4 model #s: 4250, 4300)

NOTE: Crimp connectors ARE required on D0, D, E, F, and G frame drives. NOTE: Heat shrink should comply with UL (600V, YDPU2).

31MAX.

8.2MIN.

26.5MAX.

For Terminals: R/L11, R/L12, S/L21, S/L22, T/L31, T/L32:

Power Terminal Wiring Connectors Heat Shrink Tubing:

-4

31MAX.

Ø8.2MIN.

54MAX.

Ø26.5MAX.

For Terminals: U/T1, V/T2, W/T3, +1/DC+, -/DC-

Power Terminal Wiring Connectors Heat Shrink Tubing:

42.0(MAX.)

12.2(MIN.)

42.0(MAX.)

21.0(MAX.)

70.0(MAX.)

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 2–27

Page 66

Chapter 2: Installation and Wiring

POWER MOTOR

main Terminal diagrams

frame size a main Terminals

DC-

frame size b main Terminals

DC-

frame size C main Terminals

DC-

DC+

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

2+ +1

DC+

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

2+ +1

DC+

B1 B2

Page 2–28

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 67

main Terminal diagrams (ConTinued)

frame size d0, d main Terminals

frame size e–f main Terminals

Chapter 2: Installation and Wiring

frame size g main Terminals

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 2–29

Page 68

Chapter 2: Installation and Wiring

GS4-21P0 – GS4-2030

GS4-2040 – GS4-2100

+1/DC+ & -/DC- terminals are for the connection of an optional

GS4-4250 &

+1/DC+ & -/DC- terminals are for the connection of an optional GS-xDBU

Main CirCUit wiring DiagraMs

frame sizes a, b, C main Wiring diagram, Three-phase

GS4-41P0 – GS4-4040 models 230/460VAC, 3-Phase Includes frame sizes A, B, C

Provide 3-phase input power

Fuse / NFB (No Fuse Breaker)

(L1)

(L2)

(L3)

Jumper

–

R(L1)

S(L2 )

T(L3)

DC choke (optional)

Brake resistor

frame sizes d0, d, e, f main Wiring diagram, Three-phase

GS4-4050 – GS4-200 models 230/460VAC, 3-Phase Includes frame sizes D0, D, E, F

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Fuse / NFB (No Fuse Breaker)

(L1)

(L2)

(L3)

GS-xDBU dynamic braking unit.

Do NOT connect a braking resistor directly to terminals +1/DC+ and -/DC-. Connecting a resistor directly to these terminals will damage the GS4 drive!

+1/DC+

–/DC–

R(L1)

S(L2)

T(L3)

(optional)

U(T1)

V(T2 )

W(T3)

U(T1)

V(T2)

W(T3)

Motor

3Ø

Motor

3Ø

frame size g main Wiring diagram, Three-phase

GS4-4300 models 460VAC, 3-Phase

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Fuse / NFB (No Fuse Breaker)

(L1)

(L2)

(L3)

dynamic braking unit.

Do NOT connect a braking resistor directly to terminals +1/DC+ and -/DC-. Connecting a resistor directly to these terminals will damage the GS4 drive!

+1/DC+

–/DC –

R(L11)

R(L12)

S(L21)

S(L22)

T(L31)

T(L32)

U(T1)

V(T2)

W(T3)

Motor

3Ø

Page 2–30

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 69

main CirCuiT Wiring diagrams (ConTinued)

GS4-2xxx models,

Connect 230VAC, Single-Phase power to any two of the R, S, or T terminals

single-phase main Wiring diagram, gs4 230v models

Chapter 2: Installation and Wiring

230VAC Single Phase Includes frame sizes A, B, C, D, & E

Provide single-phase input power Connect to L1 and L2 or L3

Fuse / NFB (No Fuse Breaker)

(L1)

(L2)

(L3)

Jumper

–

R(L1)

S(L2 )

T(L3)

DC choke (optional)

Brake resistor

(optional)

U(T1)

V(T2 )

W(T3)

Motor

3Ø

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 2–31

Page 70

Chapter 2: Installation and Wiring

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ConTrol Terminal speCifiCaTions

Control Circuit Terminals

Terminal Symbol +10V

-10V +24V

AI1

AI2

Description Remarks

Potentiometer Power Supply

Digital Control Signal Source +24V±5%, 200mA max output; use with DCM Analog Input 1

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Analog Input 2

Analog frequency setting: +10VDC 20mA max output Analog frequency setting: -10VDC 20mA max output

Impedance: 20kΩ Range: 0~10V → 0/4~20mA = 0~Max Output Frequency

AI1 switch = SW3; factory setting is 0~10V

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Impedance: 250Ω Range: 0/4~20mA → 0~10V = 0~Max Output Frequency

AI2 Switch = SW4; factory setting is 0~20mA

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AO1

AO2

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ACM

AO2

Analog Output 2 (internal circuit same as AO1)

Impedance: 20kΩ

Range: -10 to +10 VDC = 0~Max Output Frequency

Note: For -10V to +10V operation, connect the pot to +10V and -10V. Keep the pot wiper connected to AI3.

-10 to 10V max output current 2mA; max load 5kΩ

Re solution: 0~10V corresponds to max operation frequency

Range: 0~10V → -10 to +10V

AO1 Switch = SW1, factory setting is 0~10V

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0–10V max output current 2mA; max load 5kΩ 0–20mA max output current 20mA; max load 500Ω

Re solution: 0–10V corresponds to max operation frequency

Range: 0~10V → 0/4~20mA

AO2 Switch = SW2; factory setting is 0~10V

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Page 2–32

DIC

Digital Signal Common Rail

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Common terminal for multi-function inputs; Can be tied to DCM (for sinking) or to +24V (for sourcing)

(continued next page)

Page 71

Terminal

DOC

DCM

Symbol DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 DCM

DO1

DO2

DOC +24V ECM SCM1 SCM2 STO1 STO2

FWD

R1 R1C R1O R2 R2C

R2O

REV

RJ45-1

RJ45-2

SG+ SGSGND

Chapter 2: Installation and Wiring

Control Circuit Terminals (continued)

Description Remarks

Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 Digital Input 5 Digital Input 6 Digital Input 7 Digital Input 8 Digital Signal Common Refer to terminals FO, FWD, REV Digital Output 1

DO1

DO2

Digital Output 2 (internal circuit same as DO1)

Digital Output Common Max 48VDC, 50mA STO Control Signal Source EStop Common STO Input 1 Common STO Input 2 Common STO Input 1 STO Input 2

Digital Frequency Output

Forward Command

R1 Relay Common Re sistive Load: R1 Relay N�C� R1 Relay N�O� R2 Relay Common R2 Relay N�C�

R2 Relay N�O�

Reverse Command

RJ45 Port 1 Pins 1,2,7,8: Reserved

RJ45 Port 2

Modbus RS-485

Digital Control Ground

ON: the activation current is 3.3mA ≥ 11VDC OFF: leakage current tolerance is 1.4mA ≤ 5VDC

The AC motor drive releases various monitor signals such as drive in operation, frequency attained, and overload indication via transistor (open collector)� Can be used sinking or sourcing� Use with DOC (common terminal)� 5~48VDC / 50mA

Multi-function Output 2 (photocoupler)� Can be used sinking or sourcing� Use with DOC (common terminal)� 5~48VDC / 50mA

Safe Torque Off function� Refer to Appendix E: Safe Torque Off for more details�

High-speed pulse output� Use with DCM� Di gital Frequency Out =

Drive Output Frequency [Hz] x P3�38 [Frequency Output Multiplier]�

Duty-cycle: 50% ±1%

Min load impedance: 1kΩ/100pf

Max current: 30mA Max voltage: 30VDC

Use with DCM�

ON → forward running OFF → deceleration to stop

3A(N�O�) / 3A(N�C�); 250VAC 5A(N�O�) / 3A(N�C�); 30VDC

In ductive Load (COS 0�4):

1�2A(N�O�) / 1�2A(N�C�); 250VAC

Th ese terminals are to output monitoring signals, such as drive in

operation, frequency attained, or overload indication�

Note: R1 and R2 have N�O� and N�C� contacts� Use with DCM�

ON → reverse running OFF → deceleration to stop

Pins 3,6: SGND Pin 4: SGPin 5: SG+

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 2–33

Page 72

Chapter 2: Installation and Wiring



ConTrol Terminal bloCk diagram & Wiring speCifiCaTions

0~10V

AO1

-10~10V SW1

AO1 D01AI3AI1+10V D02D02

AO2 DOCACMAI2-10V FO

•

SW1 sets AO1: 0~10V (default) or -10 to +10V

•

SW2 sets AO2: 0~10V (default) or 0/4–20mA

•

SW3 sets AI1: 0~10V (default) or 0/4–20mA

•

SW4 sets AI2: 0/4~20mA (default) or 0~10V

•

SW5 sets RS-485: open (default) or 120Ω

0~10V

AO2

0/4~20mA

SW2

0~10V

AI1

0/4~20mA

SW3

STO2

STO1 +24V

SCM1 ECM

SCM2

+24V DIC

terminated

ConTrol Terminal Wiring insTruCTions

analog inpuTs

•

Analog input signals are easily affected by external noise� Use shielded wiring and keep it as short as possible (<20m) with proper grounding� If the noise is inductive, connect the shield to terminal ACM�

•

If the analog input signals are affected by noise from the AC motor drive, please connect a capacitor and ferrite core as indicated in the following diagram� (Wind each wire around the core 3 times or more�)

485

Open

120Ω

SW5

0/4~20mA

AI2

0~10V

SW4

FWD DI1 DI3 DI5 DI7 SGND

DCM REV DI2 DI4 DI6 DI8 SG+ SG-

Control Circuit Wiring Specifications

AC Drive Model

GS4-xxxx

Terminal

A 24~16 5 [4�3] B 26~16 8 [6�9] C 24~16 2 [1�7]

RJ45-1RJ45-2

Wire

Range

(AWG)

R1CR1R2OR2C

R1O

Tightening Torque

(kg·cm [lb·in])

Page 2–34

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•

When using contacts or switches to control the digital inputs, use high quality components to avoid contact bounce�

TransisTor ouTpuTs

•

Make sure to connect the digital outputs to the correct polarity�

•

When connecting a relay to the digital outputs, connect a surge absorber across the coil and check the polarity�

analog ouTpuTs

•

When setting SW1, and using it as a current source (external 500Ω resistor is required), ensure P4.53 AO1 0~20mA/4~20mA selection is set appropriately�

•

When seting SW2 to 0/4~20mA ensure to set P4.57 AO2 0~20mA/4~20mA selection appropriately� When setting to 0~10V (or leaving as default) ensure P4�57 is set to zero�

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 73

COntrOl CirCUit wiring DiagraMs

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DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 2–35

Page 74

Chapter 2: Installation and Wiring

SINKING Mode

* ** If P4.09 = 1, FWD/REV direction is controlled by analog input only.

ConTrol CirCuiT Wiring diagrams (ConTinued)

full i/o WiTh sinking inpuTs

(field devices are sourcing)

+24V, DCM = internal 24VDC supply and 0V

DIC = Common rail for all inputs (can be + or 0V)

For external power supply, remove all wiring from all +24V and DCM terminals

Factory

setting

NOTE

Do NOT apply mains voltage directly to above terminals.

5kΩ

NOTE

* Ensure that the physical switches for AI1 and AI2 (located above the control terminal blocks) are set for the correct voltage/current configuration.

FWD/STOP* ** REV/STOP* ** Multi-step 1* Multi-step 2* Multi-step 3* Multi-step 4*

N/A* N/A* N/A*

N/A*

0~10V / 0~20mA / 4~20mA

0~20mA / 4~20mA / 0~10V

Analog Signal Common

Modbus RS-485 BACnet

Pin 1~2, 7, 8: reserved Pin 3, 6:GND

Pin 4:SGPin 5:SG+

+10V / 20mA

0~10V / -10 to +10V

-10V / 20mA

SGND

SG+

SG-

Internal

Power

Supply

+24V

DCM

DIC

FWD

REV

DI1

DI2

DI3

DI4

DI5

DI6

DI7

DI8

+10V

SW3*

AI1*

SW4*

AI2*

AI3

ACM

-10V

45-1RJ45-2

81 81

SW1*

SW2*

R1O

R1C

R2O

R2C

AO1

ACM

AO2

Multi-function output

terminals

AC Resistive: 250VAC / 3A (N.O.) 250VAC / 3A (N.C.)

AC Inductive: 250VAC / 1.2A (N.O.) 250VAC / 1.2A (N.C.) Estimate at COS (0.4)

DC Resistive: 30VDC / 5A (N.O.) 30VDC / 3A (N.C.)

Multi-Function Output

Frequency terminals 5~30VDC / 30mA 100kHz

DCM

Digital Output terminals

DO1

5~48 VDC / 50mA

Digital Output terminals

DO2

5~48 VDC / 50mA

Digital Output common

DOC

Analog Output 1 terminal 0~10VDC / -10~+10V

Analog Signal common

Analog Output 2 terminal 0~10VDC / 4~20mA

NOTE

* Ensure that the physical switches for AO1 and AO2 (located above the control terminal blocks) are set for the correct voltage/current configuration. Use care to set these switches correctly; the setting positions are not exactly the same for both.

Page 2–36

See User Manual Appendix E for STO details.

Safety Relay, Safety PLC, or E-Stop PB (2 NC contacts required)

NOTE

* Remove factory-installed short-circuit jumper from +24V–STO1–STO2 when using STO function with internal +24VDC.

NOHC NOHC

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

ECM

SCM1

Red

SCM2

STO

+24V

Terminals

STO1

STO2

Option Slot 1

Option Slot 3

Communication extension card

I/O & RELAY extension card

Control terminalsShielded leads & Cable

Page 75

ConTrol CirCuiT Wiring diagrams (ConTinued)

SOURCING Mode

* ** If P4.09 = 1, FWD/REV direction is controlled by analog input only.

full i/o WiTh sourCing inpuTs

Chapter 2: Installation and Wiring

(field devices are sinking)

+24V, DCM = internal 24VDC supply and 0V

DIC = Common rail for all inputs (can be + or 0V)

For external power supply, remove all wiring from all +24V and DCM terminals

Factory

setting

NOTE

Do NOT apply mains voltage directly to above terminals.

5kΩ

NOTE

* Ensure that the physical switches for AI1 and AI2 (located above the control terminal blocks) are set for the correct voltage/current configuration.

FWD/STOP* ** REV/STOP* ** Multi-step 1* Multi-step 2* Multi-step 3* Multi-step 4* N/A* N/A* N/A* N/A*

+10V / 20mA

0~10V / 0~20mA / 4~20mA

0~20mA / 4~20mA / 0~10V

0~10V / -10 to +10V

Analog Signal Common

-10V / 20mA

Modbus RS-485 BACnet

Pin 1~2, 7, 8: reserved Pin 3, 6:GND

Pin 4:SGPin 5:SG+

SGND

SG+

SG-

Internal

Power

Supply

DCM

+24V

DIC

FWD

REV

DI1

DI2

DI3

DI4

DI5

DI6

DI7

DI8

+10V

SW3*

AI1*

SW4*

AI2*

AI3

ACM

-10V

45-1RJ45-2

81 81

SW1*

SW2*

Multi-function output terminals

R1O

AC Resistive:

R1C

R2O

R2C

AO1

ACM

AO2

250VAC / 3A (N.O.) 250VAC / 3A (N.C.)

AC Inductive: 250VAC / 1.2A (N.O.) 250VAC / 1.2A (N.C.) Estimate at COS (0.4)

DC Resistive: 30VDC / 5A (N.O.) 30VDC / 3A (N.C.)

Multi-Function Output

Frequency terminals 5~30VDC / 30mA 100kHz

DCM

Digital Output terminals

DO1

5~48 VDC / 50mA

Digital Output terminals

DO2

5~48 VDC / 50mA

Digital Output common

DOC

Analog Output 1 terminal 0~10VDC / -10~+10V

Analog Signal common

Analog Output 2 terminal 0~10VDC / 4~20mA

NOTE

See User Manual Appendix E for STO details.

Safety Relay, Safety PLC, or E-Stop PB (2 NC contacts required)

NOTE

* Remove factory-installed short-circuit jumper from +24V–STO1–STO2 when using STO function with internal +24VDC.

NOHC NOHC

ECM

SCM1

Red

SCM2

STO

+24V

Terminals

STO1

STO2

Control terminalsShielded leads & Cable

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Option Slot 1

Option Slot 3

Communication extension card

I/O & RELAY extension card

Page 2–37

Page 76

Chapter 2: Installation and Wiring

BLANK

PAG E

Page 2–38

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 77

chapter

Keypad OperatiOn and QuicK-Start

able of ConTenTs

The dura

GS4 Start-Up Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–4

Status Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–4

Menu Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–5

Quick-Start – Quick-Start Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–6

Keypad Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17

pulse

GS4 Digital Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–2

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 3–1

Page 78

Chapter 3: Keypad Operation and Quick-Start

the durapulse gs4 Digital keYPaD

The GS4 removable keypad can be installed flat on the surface of the control box (with or without bezel GS4-BZL) with the appropriate hole punched in the control box cover (See Arrow “A”). Use the supplied RJ45 connector and an RJ45 cable to connect to the GS4 drive. The front cover is IP56 rated. The keypad may be mounted remotely and connected to the drive with a standard RJ45 CAT5e straight through patch cable. (An RJ45 crossover cable will NOT work as the keypad extension cable.) The maximum RJ45 extension lead is 5m (16ft). No other wiring is required.

116.0 [4.57]

15.0 [0.59]72.0 [2.83]

(RJ45

connector)

RJ45 Connector Dimensions mm [in]

Descriptions of Keypad Functions

RUN Key

• Valid only when the source of operation command is from the keypad.

• The RUN LED light (above the button) turns ON when the drive is running.

• RUN can be pressed even when drive is in process of stopping.

• When in “LOCAL” mode, RUN is only valid when the source of operation command is from the keypad.

STOP/RESET Key

This key has the highest processing priority in any situation.

• When the drive receives a STOP command, whether or not the drive is in operation or stop status, the drive will execute a "STOP" command.

• The RESET key can be used to reset the drive after a fault occurs. For those faults that can't be reset by the RESET key, see the fault records after pressing MENU key for details.

NO TE: The ability to STOP the drive from the keypad is effective ONLY if the drive is configured to RUN

and/or STOP from the keypad. Keypad STOP can be disabled by parameters such as P3.00, P3.01, P3.03~P3.16.

Operation Direction Key

• This key only controls the operation direction and does NOT activate the drive. FWD: forward. REV: reverse.

• Refer to the LED descriptions for more details.

ENTER Key

Press ENTER to go to the next menu level. If it is the last level, then press ENTER to execute the command.

ESC Key

The ESC key function serves to leave the current menu and return to the last menu. It also functions as a return key while in the sub-menu.

MENU Key

Press MENU to return to the Main Menu. Menu Content:

1) Param Setup

2) Quick Start

3) Keypad Lock

4) Fault Record

5) PLC

6) Copy Param

7) Copy PLC

8) Displ Setup

Continued on next page.

9) Time Setup

10) Language

11) Start-up

Page 3–2

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Page 79

Chapter 3: Keypad Operation and Quick-Start

Descriptions of Keypad Functions (continued)

Direction: Left/Right/Up/Down

• In the numeric value setting mode, the arrows are used to move the cursor and change the numeric value.

• In the menu/text selection mode, the arrows are used for item selection.

Function Keys

• F1 is JOG function.

• The F2, F3 keys are reserved for future use. The F4 key is used to ADD parameters to the user-defined My-Menu Quick-Start Menu (see “My Menu” in the Quick-Start section of this chapter for more information).

LOCAL Key

• This key causes the drive to follow the LOCAL (2nd source) settings for frequency command and operation.* The factory settings of both source of Local frequency and Local operation are the Digital Keypad.

• Pressing the LOCAL key with the drive stopped will switch the operation and frequency to the LOCAL source (P3.01 and P4.01). Pressing the LOCAL key with the drive running can be configured to keep running or to stop upon transition. See P3.58 for more information.

• The selected mode, LOCAL or REMOTE, will be displayed on the GS4-KPD.

• When P3.58=0 then LOCAL correlates to HAND mode. The Digital Input Definition must not be set to 33 (LOC/REM Switch).

*Refer to P3.58 for more detail and other options on how the drive behaves when switching between LOCAL and REMOTE. Refer to P3.00, P3.01, P4.00 and P4.01 for defining LOCAL and REMOTE sources of operation and frequency.

REMOTE Key

• This key causes the drive to follow the REMOTE (1st source) settings for frequency command and operation.* The factory settings of both source of Remote frequency and Remote operation are the Digital Keypad.

• Pressing the REMOTE key with the drive stopped will switch the operation and frequency to the REMOTE source. Pressing the REMOTE key with the drive running can be configured to keep running or to stop upon transition. See P3.58 for more information.

• The selected mode, LOCAL or REMOTE, will be displayed on the GS4-KPD.

• When P3.58=0 then LOCAL correlates to HAND mode. The Digital Input definition must not be set to 33 (LOC/REM Switch).

Descriptions of LED Functions

Steady ON: Drive is running. Blinking: Drive is stopping or in base block. Steady OFF: Drive is not running.

Steady ON: Drive is stopped or in the process of stopping. Blinking: Drive is in standby; selected speed reference source is at zero.

(If expecting movement, confirm that a speed reference is present.)

Steady OFF: Drive is running.

NO TE: The ability to STOP the drive from the keypad is effective ONLY if the drive is configured to RUN

and/or STOP from the keypad. Keypad STOP can be disabled by parameters such as P3.00, P3.01, P3.03~P3.16.

Operation Direction LED

• Green light is on, the drive is running forward or will run forward when given a run command.

• Red light is on, the drive is running backwards or will run backwards when given a run command.

• Alternating green/red light: the drive is changing direction.

ERR_COMM_RUN

These LEDs represent the status of RS-485 communication through COM port 1.

RUN-LED Flashing: RS485 is transferring ERR-LED Red: Latest Tx or Rx failed

Off: Latest Tx or RX = OK Flashing: Please check the RS-485 master for proper configuration/communication, and also

check the PLC code for proper operation if serial comm is enabled inside the PLC.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Page 80

Chapter 3: Keypad Operation and Quick-Start

gs4 start-UP DisPlaY

At power up, the Start-up Page displays the DURApUlse, GS4 logo.

DURA

This page is replaced by the Status Page in 3 seconds. Pressing the UP Arrow while the Start-up Page is displayed will show

the current keypad firmware.

statUs Page

Drive status: Press the LOCAL key to allow local control of the drive. Press the REMOTE key to allow remote control of the drive. Pressing the Up and Down Direction keys allow the user to scroll through the Status Page items. F X.xx Hz (actual GS4 command frequency)

H X.xx Hz (actual GS4 output frequency) U XXX.x User defined value (in this example P8.00 = 3 DC bus voltage*

▲

F 60.00 Hz

▼

H 0.00 Hz

v 0.00 Vdc

JOG 14:35:36

LOCAL

A X.xx Amp (output amperage) JOG and time:

JOG appears above the F1 key and is the function assigned to that key. The GS4 internal clock is displayed, center bottom.

NOTE: When Power is applied, the keypad will display the startup Page followed by the Status Page. The Status Page displays the GS4 default settings F/H/U/A. While the order F/H/U/A is always fixed, P8.01 can be used to set which value appears on the top row at power-up. The UP and DOWN Arrows will scroll through the display options.

NOTE: If an “Err” appears on the keypad after pressing <Enter> in any menu or parameter, then the action did not take affect. The keypad will report back “End” if the action was performed correctly. Ex: writing a value out of range to a parameter will cause a “Err” message.

* NOTE: Refer to Parameter P8.00 in Chapter 4, AC Drive Parameters for a complete list of the values that can be displayed on line 3 of the keypad display. The value in P8.00 is the value that will be shown when the drive powers up. By scrolling to the User Defined row, the Left and Right Direction keys can be used to display any of the other selections available.

Page 3–4

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Page 81

MenU Page

▲

1:Param Setup

▼

2:Quick Start

3:Keypad Lock

Chapter 3: Keypad Operation and Quick-Start

Press the Menu button from any page to access the Menu Page. Use the Up and Down Direction keys to scroll through the Menu content. Press the Enter key to open the selected Menu content item. 1: Param Setup - Parameter Setup

Set up the individual drive parameters.

2: Quick Start

Set typically used parameters to allow quick drive startup.

3: Keypad Lock

Lock the Keypad.

4: Fault Record

Display fault information for the drive.

5: PLC

Run the current PLC program.

6: Copy Param - Copy Parameters

Save drive parameters to the keypad or drive.

7: Copy PLC

Copy a previously saved PLC program to the keypad or drive.

8: Displ Setup

Adjust contrast and backlight settings for the display.

9: Time Setup

Set the time.

10: Language

Set the display language.

11: Start-up

Set the Start-up Page display.

Param Setup - Parameter Setup Page

See the individual parameter summary tables in Chapter 4 - AC Drive Parameters for specific parameter explanations and settings.

00: MOTOR

Param Setup

▲

00:MOTOR

▼

01:RAMPS

02:V-Hz

01: RAMPS 02: V-Hz 03: DIGITAL 04: ANALOG 05: PRESETS 06: PROTECT 07: PID 08: DISPLAY 09: COMMUNICATION 10: PUMP 11: FAULTS

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 3–5

Page 82

Chapter 3: Keypad Operation and Quick-Start

QUiCk-start – QUiCk-start Page

The Quick Start function allows the user to set typically used parameters for quick drive startup and motor protection.

For basic applications, it may only be necessary to enter parameters into the “Basic Configuration” Menu. The “Basic” menu contains Motor definition/protection information and a bare minimum set of parameters that will need to be set. “Control I/O” allows for customization of the most common I/O settings, and each subsequent menu configures additional features and allows more customization of the drive.

If the GS4 drive has been previously configured, it is advisable to restore the default settings (by using parameter P9.08) before reconfiguring the drive.

Quick Start

▲

1:Basic Config

▼

2:Control I/O

3:Enhancements

1: basiC Config

Basic Con :P00.00

▲

01:Mtr1 Max VoltOut

▼

02:Mtr1 Amps Rated

03:Mtr1 Base Hz

The Quick Start function allows the user to quickly set typically used parameters. Not all of the six Quick Start categories need to be configured for every application, but the categories that are needed for the particular application should be configured in sequential order as shown below (starting with 1:Basic Config).

1: Basic Config 2: Control I/O 3: Enhancements 4: Protection 5: PID 6: My Menu (User Defined Quick Start Menu)

Parameters in the Basic Configuration menu:

1 P0.00 Motor 1 Maximum Output Voltage 2 P0.01 Motor 1 Rated Current 3 P0.02 Motor 1 Base Frequency 4 P0.03 Motor 1 Rated RPM 5 P0.04 Drive Maximum Output Frequency 6 P0.08 Motor 1 Rated Horsepower (HP) 7 P0.09 Motor 1 Number of Poles 8 P1.00 Stop Method 9 P1.01 Acceleration Time 1 10 P1.02 Deceleration Time 1 11 P3.00 1st Source of Operation Command [Remote] 12 P3.01 2nd Source of Operation Command [Local] 13 P4.00 1st Source of Frequency Command [Remote] 14 P4.01 2nd Source of Frequency Command [Local] 15 P6.00 Electronic Thermal Overload Relay (Motor 1) 16 P6.01 Electronic Thermal Characteristic (Motor 1) 17 P6.33 Drive Derating Method 18 P6.34 Variable/Constant Torque Duty Selection 19 P9.08 Restore to Default

Page 3–6

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Page 83

2: ConTrol i/o

Chapter 3: Keypad Operation and Quick-Start

Control I :P03.02

▲

01:2,3 wire Control

▼

02:DI1 Function

03: DI2 Function

Parameters in the Control I/O menu:

1 P3.02 2/3 Wire Operation Mode 2 P3.03 Multi-Function Input (DI1) 3 P3.04 Multi-Function Input (DI2) 4 P3.05 Multi-Function Input (DI3) 5 P3.06 Multi-Function Input (DI4) 6 P3.17 Multi-Function Output Terminal 1 (Relay 1) 7 P3.18 Multi-Function Output Terminal 2 (Relay 2) 8 P4.02 Analog Input 1 (AI1) Function 9 P4.03 Analog Input 2 (AI2) Function 10 P4.05 AI1 – I/V Selection 11 P4.06 AI2 – I/V Selection 12 P4.09 Analog Frequency Command for Reverse Run 13 P4.10 AI1 Input Bias (Offset) 14 P4.11 AI1 Input Bias (Offset) Polarity 15 P4.12 AI1 Input Gain 16 P4.13 AI1 Filter 17 P4.15 AI2 Input Bias (Offset) 18 P4.16 AI2 Input Bias (Offset) Polarity 19 P4.17 AI2 Input Gain 20 P4.18 AI2 Filter 21 P4.50 Analog Output 1 (AO1) 22 P4.51 AO1 Gain 23 P4.52 AO1 Negative Value Handle 24 P4.53 AO1 0~20mA/4~20mA Selection 25 P4.60 AO1 Output Constant Level 26 P5.01 Multi-Speed 1 27 P5.02 Multi-Speed 2 28 P5.03 Multi-Speed 3 29 P5.04 Multi-Speed 4

3: enhanCemenTs

Enhanceme :P01.09

▲

01:S Curve Acc1

▼

02:S Curve Dec1

03:Jog Acc Time

Parameters in the Enhancements menu:

1 P1.09 S-curve Accel Time 1 2 P1.10 S-curve Decel Time 1 3 P1.13 Jog Acceleration Time 4 P1.14 Jog Deceleration Time 5 P5.00 Jog Frequency 6 P1.19 Skip Frequency 1 Upper Limit 7 P1.20 Skip Frequency 1 Lower Limit 8 P1.25 DC Injection Current Level 9 P1.26 DC Injection Time During Start-up 10 P1.27 DC Injection Time During Stopping 11 P1.28 Start-Point for DC Injection During Stopping 12 P2.00 Volts/Hertz Settings 13 P2.01 Slip Compensation Gain 14 P2.25 Slip Compensation Filter 15 P2.02 Torque Compensation Gain 16 P2.03 Torque Compensation Filter 17 P2.10 PWM Carrier Frequency 18 P2.11 Control Mode 19 P2.18 Zero Speed Select 20 P6.25 Upper Limit of Output Frequency 21 P2.23 Automatic Energy-Saving Operation 22 P2.24 Power Saving Gain 23 P2.26 Slip Deviation Level 24 P2.27 Slip Deviation Detection time 25 P2.28 Slip Deviation Treatment

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

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Page 84

Chapter 3: Keypad Operation and Quick-Start

4: proTeCTion

Protectio :P06.04

▲

01:Auto Restart Qty

▼

02:Reset Window

03:BB Spd Searc

5: pid

PID :P7.00

▲

01:PID Fbk Select

▼

02:Rem Freq Src

03:Loc Freq Src

Parameters in the Protection menu:

1 P6.04 Auto Restart after Fault 2 P6.05 Reset Time for Auto Restart after fault 3 P6.06 Base Block Speed Search after Fault (oc,ov,bb) 4 P6.09 Fwd/Rev Direction Inhibit 5 P6.13 Auto Adjustable Accel/Decel 6 P6.14 Over-torque Detection Mode (OT1) 7 P6.15 Over-torque Detection Level (OT1) 8 P6.16 Over-torque Detection Time (OT1) 9 P6.26 Lower Limit of Output Frequency 10 P6.28 Dynamic Braking Voltage Level 11 P6.29 Line Start Lockout 12 P6.31 Cooling Fan Control 13 P6.32 PWM Fan Speed 14 P6.45 Output Phase Loss (OPhL) Detection Selection 15 P6.46 Output Phase Loss Detection time 16 P6.47 Output Phase Loss Current Detection Level 17 P6.49 Input Phase Loss Treatment 18 P6.69 Input Phase Loss Detection Time 19 P6.70 Input Phase Loss Ripple Detection 20 P6.50 GFF Detect Current Level (% of INV I-Rated) 21 P6.51 GFF Low Pass Filter Gain 22 P6.71 STO Alarm Latch

Parameters in the PID menu:

1 P7.00 PID Action/Mode 2 P4.00 1st Source of Frequency Command [Remote] 3 P4.01 2nd Source of Frequency Command [Local] 4 P4.02 Analog Input 1 (AI1) Function 5 P4.03 Analog Input 2 (AI2) Function 6 P4.04 Analog Input 3 (AI3) Function 7 P4.05 AI1 – I/V Selection 8 P4.06 AI2 – I/V Selection 10 P7.03 PID Feedback Gain 11 P7.04 PID Offset Value 12 P7.13 Proportional Gain 13 P7.14 Integral Time 14 P7.15 Derivative Value 15 P7.18 PID Output Frequency Limit 16 P7.20 Feedback Signal Detection Time 17 P7.21 PID Feedback Loss 18 P7.22 PID Feedback Loss Speed Level Default 19 P7.25 PID Mode Selection 20 P7.26 PID Reverse Enable 21 P8.00 User Display 22 P8.01 Start-up Display Selection 23 P8.02 User Defined Format 24 P8.03 User Defined Max 25 P8.04 User Defined Setpoint

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Page 85

6: my menu

Chapter 3: Keypad Operation and Quick-Start

My Menu

▲

01:

▼

02:

03:

Param Setup

▲

00:MOTOR

▼

01:RAMPS

02:Volts/Hertz

00-01 Amps

Press ENTER to Save MyMenu

My Menu allows the user to store up to 32 parameters of their choosing into a custom Quick Start menu. Storing parameters in the My Menu menu can be accomplished in two steps.

Step 1:

From the main menu, go to the parameter you want to add under “1: Param Setup.”

Step 2:

When you are on the page where you can adjust the parameter value, notice that the word ADD is above function key F4. Press the F4 key to ADD the displayed parameter to “My Menu”.

Select the desired parameter group and parameter to include in the My Menu menu. Press Enter to add the selected parameter to My Menu.

My Menu P00-01

▲

01:Motor1 Rate

▼

02:Multi-Speed

03:

00-01 Amps

▲ ▼

4.50

Motor1 Rated A

0.50~6.00 DEL

To delete a My Menu parameter, in the My Menu menu, position the cursor next to the parameter you wish to delete and press Enter.

Notice that “DEL” appears above the F4 key. Press the F4 key and then Enter to delete from My Menu.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 3–9

Page 86

Chapter 3: Keypad Operation and Quick-Start

Keypad Lock - Keypad Lock Page

Keypad Lock

Press ENTER to

Lock Key

Keypad Lock is used to lock the keypad from unintentional activation during operation.

Press the Enter key to lock the keypad.

▲

F 60.00 Hz

▼

H 0.00 Hz

v 335.6 Vdc

JOG 03:45:36

Keypad Lock

Press ESC 3sec

to UnLock Key

▲

F 60.00 Hz

▼

H 0.00 Hz

LOCAL

The Status Page will again display.

Pressing ANY key will display the message Press ESC to UnLock Key.

Press and hold the ESC key for 3 seconds to unlock the keypad. The display will return to the Status Page.

Page 3–10

v 335.6 Vdc

JOG 03:46:12

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 87

Fault Record - Fault Record Page

GS4 drive faults are stored from 1: to 20:. Refer to Chapter 6: Maintenance and Troubleshooting for a complete list of fault messages

that may appear. Use the Up and Down Direction keys to scroll

Fault Record

▲

001: Lvn

▼

002:

003:

through the list. 1:

2: 3: ▲ ▼ 18: 19: 20:

Press the Enter key to display information about the drive status when the fault occurred.

Chapter 3: Keypad Operation and Quick-Start

1: Lvn

▲

Date:05/15/2016

▼

Time: 08:51:10

OutFreq: 60.00

Date: 00/00/0000 Time: 00:00:00 OutFreq: 0.00 OutAmp: 0.00 OutVolt 0.0 DCBus: 0.0

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 3–11

Page 88

Chapter 3: Keypad Operation and Quick-Start

PLC - PLC Function Page

PLC

▼

1:Disable ☻

2:PLC Run

3:PLC Stop

PLC/RUN LOC

▲

F 60.00 Hz

▼

H 0.00 Hz

v 335.6 Vdc

JOG 04:10:16

PLC Function is used to Enable/Disable and Run/Stop the internal PLC. The active selection is marked by a smiley face character on the far right of the display.

WARNING: oN A poWeR cycle the plc RuN/stop stAte WIll be

deteRmINed by the lAst stAte the keypAd WAs plAced IN, oR by the coNfIGuRed dIGItAl INputs. If the stAte WAs chANGed vIA

GsloGIc, thAt RuN/stop stAte mAy Not be tRue oN A poWeR cycle.

Use the Up and Down Direction keys to select Disable, PLC Run or PLC Stop.

Press the Enter key to confirm the selection.

Selecting PLC Run will activate the GS4 internal PLC. The keypad status Page will display PLC/RUN at the top, center of the display. If PLC Stop is selected, the PLC program will stop and the Status Page will display PLC/STOP at the top center of the page. Selecting Disable will disable the GS4 internal PLC and return control to the drive. Selecting PLC Run or PLC Stop also can determine whether the physical I/O are controlled by the Drive or are controlled by the PLC. See Chapter 8 for more information on the integrated PLC and GSLogic software.

Page 3–12

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Chapter 3: Keypad Operation and Quick-Start

Copy Param - Copy Parameters Page (Keypad Copy)

Copy Parameters is used to save up to four drive configurations into the keypad. The keypad can then download any of these

Copy Param

▲

001:

▼

002:

003:

001>

▼

1:Keypad→VFD

2:VFD→Keypad

configurations into the drive, or it can be moved to a different drive and download the parameter settings of the original drive. Use the Up and Down Direction keys to scroll through the four available copy parameter locations. If a field is blank, then no copy has been made to that location. 001: ExhaustFan

002: IntakeFan1 003: Filename02 004:

Press the Enter key to select the desired location for writing the current parameter settings.

Use the Up and Down Direction keys to select Keypad→VFD to copy the current parameter settings from the keypad to the drive or VFD→Keypad to write the current parameter settings from the drive to the keypad. Press the Enter key.

VFD→ KeypaD

001>

ExhaustFan

KeypaD→ VFD

001> P00-00

Keypad→VFD

10%

When VFD→Keypad is selected, the keypad will prompt you for a filename to save the existing configuration into. Use the Left/Right Arrows to scroll from character to character and the Up/Down Arrows to change the alphanumeric character. Pressing Enter will begin the transfer of parameters from the drive into the keypad.

When Keypad→VFD is selected, the keypad will begin the transfer of the preselected file parameters from the keypad into the drive.

As shown in the example to the left, “001” is the file to be transferred.

(NOTE: P9.06, Parameter Copy Enable, must first be set to 1.)

Pressing F4 while in the Copy Param menu will prompt you to Delete All 4 saved programs (“Press ENTER to clear”).

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 3–13

Page 90

Chapter 3: Keypad Operation and Quick-Start

Copy PLC - Copy PLC Page

Copy PLC

▲

001:

▼

002:

003:

001>

▼

1: Keypad→VFD

2: VFD→Keypad

Copy PLC is used to copy previously saved PLC program from the keypad to the drive or from the drive to the keypad. Use the Up and Down Direction keys to scroll through the four available Copy PLC locations. If the field is blank, then no copies have been made.

Press the Enter key to select the desired location for writing the current program.

Use the Up and Down Direction keys to select Keypad→VFD to copy the previously saved PLC settings from the keypad to the drive or VFD→Keypad to write the current PLC program from the drive to the keypad.

VFD→ KeypaD

001>

ExhaustPLC

KeypaD→ VFD

001> P00-00

Keypad→VFD

10%

When VFD→Keypad is selected, the keypad will prompt you for a filename to save the existing configuration into. Use the Left/Right arrows to scroll from character to character and the Up/Down arrows to change the alphanumeric character. Pressing Enter will begin the transfer of PLC program from the drive into the keypad.

When Keypad→VFD is selected, the keypad will begin the transfer of PLC program from the keypad into the drive.

Page 3–14

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 91

Displ Setup - Display Setup Page

Chapter 3: Keypad Operation and Quick-Start

Displ Setup

▼

1:Contrast

2:Back-Light

3:Text Color

Contrast

-5

-10 0 +5

Back-Light Min

0 10

Text Color

White Text

0~1

The Display Setup Page allows the user to adjust the Contrast, Backlight time and Text Color of the display.

1: Contrast 2: Backlight 3: Text Color

Use the Up and Down direction arrows to adjust the Contrast to the desired setting. The range of adjustment is from -20 to +20. The default value is 0.

Use the Up and Down direction arrows to adjust the time when the display backlight turns off. The range of adjustment is from 0 to 10 minutes. The default value is 5 minutes.

Use the Up and Down direction arrows to select from white text or blue text for the display.

Time Setup - Time Setup Page

The Time Setup Page allows the user to change the date and time.

Time Setup

2016/05/15

21:57:40

The date format is Year/Month/Day. Time is displayed in 24-hour clock format and is displayed as Hours:Minutes:Seconds. Use the Right and Left Arrow keys to move the cursor to the desired location and use the Up and Down Arrow keys to adjust the setting.

After adjusting the time, move the cursor to the Seconds entry before pressing the Enter Key.

The real time clock (RTC) is maintained in the keypad. A capacitor is used to provide power for the RTC during power loss. The capacitor can maintain power for the RTC for 7 days with no drive power applied.

Language - Language Page

Language

▼

1:English ☻

2:Espanol

3:Francaise

The Language Page sets the language shown on the display. Select from English, Spanish or French.

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 3–15

Page 92

Chapter 3: Keypad Operation and Quick-Start

Start-up - Start-up Page

Start-up

▼

1:Default1 ☻

2:Default2

The Start-up Page allows the user to select from three different screens that display during initial start-up. Default1 setting displays the GS4 logo screen, Default2 setting displays “Initializing, Please Wait.”

Page 3–16

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 93

keYPaD faUlt CODes

Following are the fault codes and descriptions for the GS4-KPD. To reset the fault codes press the Enter and Reset buttons simultaneously. These faults indicate either a communication error between the keypad and the drive or a keypad failure. To correct: 1) Inspect and clean the RJ45 connectors on the back of the keypad and the RJ45 connector leading into the drive. 2) Replace the cable and/or RJ45 M-M adapter with a standard Ethernet patch cable. 3) If the RJ45 connections are OK, replace the keypad.

Chapter 3: Keypad Operation and Quick-Start

Display error signal

①

Fault

②

③

kpdFlash Read Er

ID No. Description Corrective Actions

Fault

FrEr

kpdFlash Read Er

Fault

FSEr

kpdFlash Save Er

Fault

FPEr

kpdFlash Pr Er

Fault

VFDr

Read VFD Info Er

Fault

ERR88

Type Mismatch

FrEr

LOCAL

②

③

Keypad flash memory read error.

Keypad flash memory save error.

Keypad flash memory parameter error.

Keypad flash memory when read AC data error.

Keypad/Drive parameter file mismatch.

Abbreviated error code The code is displayed as shown on GS4-KPD

Display error description

An error has occurred on keypad’s flash memory.

1. Press RESET on the keypad to clear the error.

2. Verify what kind of error has occurred on keypad’s flash memory.

3. Shut down the system, wait 10 minutes and power up the system.

If the error remains contact technical support. An error has occurred on keypad’s flash memory.

1. Press RESET on the keypad to clear the error.

2. Verify what kind of error has occurred on keypad’s flash memory.

3. Shut down the system, wait 10 minutes and power up the system.

If the error remains contact technical support. Errors occurred on factory setting parameters possibly caused by

firmware update.

1. Press RESET on the keypad to clear the error.

2. Verify if there is a problem on the FLASH IC.

3. Shut down the system, wait 10 minutes and power up the system.

If the error remains contact technical support. Keypad can’t read data from drive.

1. Verify if the keypad is properly connected to the drive with the

RJ45 connector.

2. Press RESET on the keypad to clear the error.

3. Shut down the system, wait 10 minutes and power up the system.

If the error remains contact technical support.

There has been an attempt to copy an incorrect file between the keypad and the drive. Ensure that there is a valid file in the keypad

(if attempting Keypad → VFD transfer).

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 3–17

Page 94

Chapter 3: Keypad Operation and Quick-Start

BLANK

PAG E

Page 3–18

DuRApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 95

ChAPter

AC Drive PArAmeters

able oF contents

DURAPulse GS4 Parameter Summary � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–2

Motor Parameters Summary (P0�xx) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–2 Ramps Parameters Summary (P1�xx) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–3 V/Hz Parameters Summary (P2�xx) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–4 Digital Parameters Summary (P3�xx) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–6 Analog Parameters Summary (P4�xx)� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–10 Presets Parameters Summary (P5�xx)� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–14 Protection Parameters Summary (P6�xx) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–15 PID Parameters Summary (P7�xx)� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–19 Display Parameters Summary (P8�xx) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–21 Serial Communication Parameters Summary (P9�xx) � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–24 Pump Parameters Summary (P10�xx)� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–29 Fault Parameters Summary (P11�xx) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–30

DURAPulse GS4 Parameter Details� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–33

Explanation of Parameter Details format � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–33 Group P0�xx Details – Motor Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–33 Group P1�xx Details – Ramps Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–39 Group P2�xx Details – V/Hz Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–49 Group P3�xx Details – Digital Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–63 Group P4�xx Details – Analog Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–93 Analog Input Parameter Examples � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–112 Group P5�xx Details – Presets Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–123 Group P6�xx Details – Protection Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–125 Group P7�xx Details – PID Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–164 Group P8�xx Details – Display Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–174 Group P9�xx Details – Serial Communication Parameters � � � � � � � � � � � � � � � � � � � � � � � � 4–181 Block Transfer Explanation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–192 Group P10�xx Details – Pump Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–193 Pump Parameters Details � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–194 Timing Charts for Circulative Control Modes P10�01 through P10�08� � � � � � � � � � � � � � � � � � 4–197 Terminal Specifications for GS4-06TR (Optional Six-Relay Output Card) � � � � � � � � � � � � � � � � 4–203 Wiring Diagrams for Cyclical Pump Control � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–203 Group P11�xx Details – Fault Parameters� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4–206

DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 4–1

Page 96

Chapter 4: AC Drive Parameters

duraPulse GS4 Parameter Summary

Motor ParaMeters suMMary (P0.xx)

For detailed information about the P0.xx parameter group, please refer to page 4–33.

GS4 Parameters Summary – Motor Parameters (P0.xx)

Run1)

Parameter Range

Read/ Write

1) ♦ in the Run-Read/Write column indicates that the parameter can be set during RUN mode. R/W indicates “read/write.” Read indicates “read-only.”

2) Parameters can be restored to their default values using P9.08.

P0.00

P0.01

P0.02

P0.03

P0.04

P0.05

P0.06

P0.07

P0.08

P0.09

P0.10

P0.11

P0.12

P0.13

P0.14

P0.15

P0.16

P0.17

P0.18

Motor 1 Maximum Output Voltage

Motor 1 Rated Current 10~120% drive rated Amps R/W 0001 40002

Motor 1 Base Frequency 0�00~600�00 Hz R/W 0002 40003 60�00

Motor 1 Rated RPM 0 to (120 x P0�02/P0�09)-1 ♦R/W 0003 40004

Drive Maximum Output Frequency

Motor Auto Tune

Motor 1 Resistance 0~65.535Ω R/W 0006 40007 0

Motor 1 No-Load Current 0~100% motor rated Amps R/W 0007 40008

Motor 1 Rated Horsepower (HP) 0�00~655�35hp ♦R/W 0008 40009

Motor 1 Number of Poles 2 to (120 x P0�02/P0�03) R/W 0009 40010 4

Motor 1 or 2 Selection

Motor 2 Maximum Output Voltage

Motor 2 Rated Current 10~120% drive rated Amps R/W 000C 40013

Motor 2 Base Frequency 0�00~600�00 Hz R/W 000D 40014 60�00

Motor 2 Rated RPM 0 to [(120 x P0�13/P0�18)-1] rpm ♦R/W 000E 40015

Motor 2 Resistance 0~65.535Ω R/W 000F 40016 0

Motor 2 No-Load Current 0~100% motor rated Amps R/W 0010 40017

Motor 2 Rated Horsepower (HP) 0�00~655�35 hp ♦R/W 0011 40018

Motor 2 Number of Poles 2 to (120 x P0�13/P0�14) R/W 0012 40019 4

230V: 0�0~255�0V 460V: 0�0~510�0V

0~600�00 Hz R/W 0004 40005 50�00/60�00

0: Disable 1: Measure motor in dynamic status

(motor spinning)

2: Measure motor in static status

(motor not spinning)

1: Motor 1 2: Motor 2

230V: 0�0~255�0V 460V: 0�0~510�0V

R/W 0000 40001

R/W 0005 40006 0

R/W 000A 40011 1

R/W 000B 40012

Modbus Address Hex Dec Default2)User

Settings

GS4 -2xxx:

230�00

GS4 -4xxx:

460�00

90% rated I of GS4

17 10 (60Hz

4-pole)

14 10 (50Hz

4-pole)

40% of Motor1 Rated I

Rated hp of GS4

GS4 -2xxx:

230�00

GS4 -4xxx:

460�00

90% rated I of GS4

17 10 (60Hz

4-pole)

14 10 (50Hz

4-pole)

40% of Motor2 Rated I

Rated hp of GS4

Page 4–2

DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 97

Chapter 4: AC Drive Parameters

raMPs ParaMeters suMMary (P1.xx)

For detailed information about the P1.xx parameter group, please refer to page 4–39.

GS4 Parameters Summary – Ramps Parameters (P1.xx)

Run1)

Parameter Range

Read/ Write

1) ♦ in the Run-Read/Write column indicates that the parameter can be set during RUN mode. R/W indicates “read/write.” Read indicates “read-only.”

2) Parameters can be restored to their default values using P9.08.

P1.00

P1.01 P1.02 P1.03 P1.04 P1.05 P1.06 P1.07 P1.08 P1.09 P1.10 P1.11 P1.12 P1.13 P1.14

P1.15

P1.16

P1.17 P1.18 P1.19 P1.20 P1.21 P1.22 P1.23 P1.24 P1.25 P1.26

P1.27

P1.28

P1.29

Stop Method

Acceleration Time 1 Deceleration Time 1 ♦R/W 0102 40259 10�00 Acceleration Time 2 ♦R/W 0103 40260 10�00 Deceleration Time 2 ♦R/W 0104 40261 10�00 Acceleration Time 3 ♦R/W 0105 40262 10�00 Deceleration Time 3 ♦R/W 0106 40263 10�00 Acceleration Time 4 ♦R/W 0107 40264 10�00 Deceleration Time 4 ♦R/W 0108 40265 10�00 S-curve Accel Time 1 S-curve Decel Time 1 ♦R/W 010A 40267 0�20 S-curve Accel Time 2 ♦R/W 010B 40268 0�20 S-curve Decel Time 2 ♦R/W 010C 40269 0�20 Jog Acceleration Time Jog Deceleration Time ♦R/W 010E 40271 10�00 Time Unit for Accel/Decel &

S-curve

Accel/Decel Transition Method

Accel Transition Frequency 1-2 Decel Transition Frequency 1-2 ♦R/W 0112 40275 0�00 Skip Frequency 1 Upper Limit Skip Frequency 1 Lower Limit R/W 0114 40277 0�00 Skip Frequency 2 Upper Limit R/W 0115 40278 0�00 Skip Frequency 2 Lower Limit R/W 0116 40279 0�00 Skip Frequency 3 Upper Limit R/W 0117 40280 0�00 Skip Frequency 3 Lower Limit R/W 0118 40281 0�00 DC Injection Current Level 0~100% ♦R/W 0119 40282 0 DC Injection Time During Start-up DC Injection Time During

Stopping Start-Point for DC Injection During

Stopping

Deceleration Method

0: Ramp to stop 1: Coast to stop

P1�15=0: 0�00~600�00 sec P1�15=1: 0�0~6000�0 sec

P1�15=0: 0�00~25�00 sec P1�15=1: 0�0~250�0 sec

P1�15=0: 0�00~600�00 sec P1�15=1: 0�0~6000�0 sec

0: unit 0�01sec 1: unit 0�1sec

0: rmp2 from terminal 1: transition frequencies P1�17 & P1�18

0�00~600�00 Hz

0�0~60�0 sec

0�00~600�00 Hz ♦R/W 011C 40285 0�00

0: Normal Ramp Deceleration 1: Over Fluxing Deceleration 2: Traction Energy Control

♦R/W 0100 40257 0

♦R/W 0101 40258 10�00

♦R/W 0109 40266 0�20

♦R/W 010D 40270 10�00

R/W 010F 40272 1

♦R/W 0110 40273 0

♦R/W 0111 40274 0�00

R/W 0113 40276 0�00

♦R/W 011A 40283 0�0

♦R/W 011B 40284 0�0

R/W 011D 40286 0

Modbus Address Hex Dec Default2)User

Settings

DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 4–3

Page 98

Chapter 4: AC Drive Parameters

v/hz ParaMeters suMMary (P2.xx)

For detailed information about the P2.xx parameter group, please refer to page 4–49.

GS4 Parameters Summary – V/Hz Parameters (P2.xx)

Run1)

Parameter Range

Read/ Write

1) ♦ in the Run-Read/Write column indicates that the parameter can be set during RUN mode. R/W indicates “read/write.” Read indicates “read-only.”

2) Parameters can be restored to their default values using P9.08.

0: General Purpose 1: High Starting Torque

(TQR)

P2.00

P2.01

P2.02 P2.03 P2.04

P2.05

P2.06

P2.07

P2.08

P2.09

P2.10

P2.11

P2.12

P2.13

P2.14

Volts/Hertz Settings

Slip Compensation Gain 0�00~10�00 ♦R/W 0201 40514

Torque Compensation Gain 0~10 ♦R/W 0202 40515 0 Torque Compensation Filter 0�001~10�000 sec ♦R/W 0203 40516 0�5 Motor 1 Middle Output Frequency 1 0�00~600�00 Hz R/W 0204 40517 3�00

Motor 1 Middle Output Voltage 1

Motor 1 Middle Output Frequency 2 0�00~600�00 Hz R/W 0206 40519 3�00

Motor 1 Middle Output Voltage 2

Motor 1 Minimum Output Frequency 0�00~599�99 Hz R/W 0208 40521 1�50

Motor 1 Minimum Output Voltage

PWM Carrier Frequency Note: there are iNterdepeNdeNcies

betweeN p2.10, p6.00/p6.02, p6.33,

p6.34. refer to parameter details

wheN settiNg these parameters.

Control Mode

Motor 2 Middle Output Frequency 1 0�00~600�00 Hz R/W 020C 40525 3�00

Motor 2 Middle Output Voltage 1

Motor 2 Middle Output Frequency 2 0�00~600�00 Hz R/W 020E 40527 3�00

2: Fans and Pumps 3: Custom 4: 1�5 Power Curve 5: Square Curve

230V: 0�0~240�0V 460V: 0�0~480�0V

23 0V: 0�0~240�0V 46 0V: 0�0~480�0V

2~15 kHz R/W 020A 40523

0: V/Hz Open Loop Control 1: SVC Sensorless

230V: 0�0~240�0V 460V: 0�0~480�0V

R/W 0200 40513 0

♦R/W 0205 40518

♦R/W 0207 40520

♦R/W 0209 40522

♦R/W 020B 40524 0

♦R/W 020D 40526

(table continued next page)

Modbus Address

Settings

Hex Dec Default

0� 00

(V/Hz mode)

1� 00

(Vector mode)

G S4-

21P0~27P5: 15�0V 2010+: 14�0V

G S4-

41P0~47P5: 30�0V 4010+: 28�0V

G S4-

21P0~27P5: 15�0V 2010+: 14�0V

G S4-

41P0~47P5: 30�0V 4010+: 28�0V

G S4-

21P0~27P5: 9�0V 2010+: 7�0V

G S4-

41P0~47P5: 18�0V 4010+: 14�0V

model specific; refer to param� details

G S4-

21P0~27P5: 15�0V 2010+: 14�0V

G S4-

41P0~47P5: 30�0V 4010+: 28�0V

User

Page 4–4

DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 99

GS4 Parameters Summary – V/Hz Parameters (P2.xx) – (continued)

Parameter Range

P2.15

P2.16

P2.17

P2.18

P2.19 P2.20

P2.21

P2.22

P2.23

P2.24 P2.25 P2.26 P2.27

P2.28

P2.29

Motor 2 Middle Output Voltage 2

Motor 2 Minimum Output Frequency 0�00~599�99 Hz R/W 0210 40529 1�50

Motor 2 Minimum Output Voltage

Zero Speed Select

Start Frequency 0�00~600�00 Hz R/W 0213 40532 0�50 Y-D Switching Frequency 0�00~600�00 Hz ♦R/W 0214 40533 60�00

Y-D Switching Enable

Delay Time for Y-D Switching 0�00~600�00 Hz ♦R/W 0216 40535 0�200

Automatic Energy-Saving Operation

Power Saving Gain 10~1000% ♦R/W 0218 40537 100 Slip Compensation Filter 0�001~10�000 sec ♦R/W 0219 40538 0�100 Slip Deviation Level 0�0~100�0 ♦R/W 021A 40539 0�0 Slip Deviation Detection time 0�0~10�0 ♦R/W 021B 40540 1�0

Slip Deviation Treatment

Hunting Gain 0~10000 ♦R/W 021D 40542 1000

230V: 0�0~240�0V 460V: 0�0~480�0V

23 0V: 0�0~240�0V 46 0V: 0�0~480�0V

0: Standby 1: Zero Hold 2: Fmin (Min Hz Output)

0: Disable 1: Enable

0: Warn and continue OP 1: Warn and Ramp to Stop 2: Warn and Coast to stop 3: No Warn

Chapter 4: AC Drive Parameters

Run Read/ Write

♦R/W 020F 40528

♦R/W 0211 40530

R/W 0212 40531 0

R/W 0215 40534 0

♦R/W 0217 40536 0

♦R/W 021C 40541 0

Modbus Address

Settings

Hex Dec Default User

G S4-

21P0~27P5: 15�0V 2010+: 14�0V

G S4-

41P0~47P5: 30�0V 4010+: 28�0V

G S4-

21P0~27P5: 9�0V 2010+: 7�0V

G S4-

41P0~47P5: 18�0V 4010+: 14�0V

DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017

Page 4–5

Page 100

Chapter 4: AC Drive Parameters

digital ParaMeters suMMary (P3.xx)

For detailed information about the P3.xx parameter group, please refer to page 4–63.

GS4 Parameters Summary – Digital Parameters (P3.xx)

Run1)

Parameter Range

Read/ Write

1) ♦ in the Run-Read/Write column indicates that the parameter can be set during RUN mode. R/W indicates “read/write.” Read indicates “read-only.”

2) Parameters can be restored to their default values using P9.08.

P3.00

P3.01

P3.02

1st Source of Operation Command [Remote]

2nd Source of Operation Command [Local]

2/3 Wire Operation Mode

0: Digital Keypad 1: External Terminal; Keypad/RS-485 STOP is

enabled

2: External Terminal; Keypad/RS-485 STOP is

disabled

3: RS485 (Modbus/BACnet); Keypad STOP is

enabled

4: RS485 (Modbus/BACnet); Keypad STOP is

disabled 5: Comm Card; Keypad STOP is enabled 6: Comm Card; Keypad STOP is disabled

0: 2-wire mode 1 (Fwd, Rev) 1: 2-wire mode 2 (Run, Direction) 2: 3-wire mode

R/W 0300 40769 0

R/W 0301 40770 0

R/W 0302 40771 0

(table continued next page)

Modbus Address Hex Dec Default2)User

Settings

Page 4–6

DURApulse GS4 AC Drive User Manual – 1st Ed, Rev A - 10/20/2017