AutomationDirect GS20X Installation Manual

DURApulse GS20X NEMA 4X AC Drive Quick-Start Guide

R/L1

S/L2

T/L3*

R/L1

S/L2

T/L3*

U/T1

V/T2

W/T3

3

~

R1C

R1

R1C and R1 are the relay output terminals.

Input: one-phase / three-phase* power

DC reactor (optional)

Brake resistor (optional)

Jumper

Motor

Circuit Breaker or Fuse

MC

ON

MC

OFF

It is recommended that
you install a protective
circuit at R1C – R1 to
protect the drive from
damage.

When a fault occurs, the MC contactor
switches to OFF to shut off the Drive Input
Power and protect the power system.

MC

DO

DCM

Multi-function output
frequency terminals
30 VDC / 30 mA 33 kHz

DO2

DOC

DO1

Multi-function output
terminal 48 VDC / 50 mA

Multi-function output
terminal 48 VDC / 50 mA

Multi-function output
common terminal (photocoupler)

USB Port

Communication card/
DC 24V external power supply card

Option Slot

250 VAC / 3 A (N.O.)

250 VAC / 3 A (N.C.)

R1O

R1C

R1

250 VAC / 1.2 A (N.O)

Multi-function relay output terminals

Estimate at COS (0.4)

Modbus RS-485

8

1

S

G

+

S

G

N

D

Control terminals

Shielded leads & Cable

Main circuit terminals

NOT

E

DI1/FWD

DI2/REV

DI3

DI4

DI5

DI6

DI7

DCM

+

24V

+

24V

Default

FWD/STOP

REV/STOP

Multi-step speed 1

Multi-step speed 2

Multi-step speed 3

Multi-step speed 4

N/A

Digital Signal Common

*DI7 can input 33 kHz pulses.
*Do NOT apply the mains voltage directly to
external terminals.

Default:
NPN (SINK) Mode (internal power)
Please refer to the wiring of NPN mode and PNP mode.

STO1

+24 V

STO2

ESTOP

+24 VDC

Safety PLC

NOT

E

SCM

*

1

It is a short circuiting jumper installed between
+24 V, S1 and S2 short when GS20 leaves the factory.
Remove this short circuiting jumper before using the
safety function while wiring.

*

1:

*

2:

The +24 V is for STO only, and cannot be used for any
other purpose.

2

*

AI1

ACM+10V

3

2

1

0 – 10 VDC

AI2

0 – 10 VDC

+

10 VDC / 20 mA

-10 VDC – 10 VDC

0 – 20 mA / 4

–

20 mA

Analog Signal common

Analog Multi-function output
terminal 0 – 10 VDC /
0 – 20 mA / 4 – 20 mA

Analog Signal common

+

5KΩ

P

N

P

NPN

P

N

P

N
P
N

0

-

1

0

V

AFM

–

0

-

1

0

V

AO1

–

20 mA

0

–

10 V

0

-

2

0

m

A

4-2

0

m

A

ACI

0 – 20 mA

4 – 20 mA

0

-

2

0

m

A

4-2

0

m

A

AI2

0

–

4

–

0

–

AO1

GS20X AC Drives Installation Instructions

NEMA 4X Sensorless Vector Control Variable Frequency
Micro-drive

• Please read this instruction sheet thoroughly before installation and retain for later
reference.

• To ensure the safety of operators and equipment, only qualified personnel familiar with
AC drives should install, wire, program, and operate the GS20X drive. Always read this
instruction sheet thoroughly before using the GS20X drive, especially the WARNING,
DANGER and CAUTION notes. If you have any questions, please contact AutomationDirect.

PLEASE READ PRIOR TO INSTALLATION FOR SAFETY

• The ground terminal of the GS20X drive must be grounded correctly. The grounding method
must comply with the laws of the country where the GS20X drive is to be installed.

• After power has been turned off, the capacitors in the GS20X drive may retain a charge
for several minutes. To prevent personal injury, visually verify that the “CHARGE” LED has
turned off. Then measure to confirm that the DC bus voltage level between terminals (+1)
and (-) is less than 25VDC before touching any terminals. (Capacitor discharge will take at
least 5 minutes for most GS20X models)

• The CMOS ICs on the internal circuit boards of the GS20X drive are sensitive to static
electricity. Please DO NOT touch the circuit boards with your bare hands before taking

DANGER

WARNING

CAUTION

anti-static measures. Never disassemble the internal components or circuits.

• If wiring changes must be made, turn off power to the GS20X drive before making those
changes. Allow the internal DC bus capacitors in the GS20X drive sufficient time to discharge
prior to making changes in power or control wiring. Failure to do so may result in short
circuit and fire. To ensure personal safety, allow DC bus voltage to discharge to a safe level
before making wiring changes to the GS20X drive.

• DO NOT install the GS20X drive in locations subject to high temperature, direct sunlight, or
flammable materials.

• Never apply power to the output terminals U/T1, V/T2, W/T3 of the GS20X drive. If a
fault occurs during operation of the GS20X drive, refer to the fault code descriptions and
corrective actions to reset the fault before attempting to operate the GS20X drive.

• DO NOT use Hi-pot test for internal components. The semi-conductors in the GS20X drive
are easily damaged by high voltage.

• Long motor lead lengths may result in reflective wave due to impedance mismatch between
the motor cable and the motor. Reflective wave may damage the insulation of the motor.
To avoid the possibility of reflective wave damage, use an inverter-rated motor with an
insulation rating of 1600 volts. A load reactor installed between the GS20X drive and motor
will help to mitigate reflective wave.

• Nominal supply voltage to the GS20X drive should be less than or equal to 120/240/480 volts
AC depending on GS20X model.

• Nominal supply current capacity should be less than or equal to 100kA for all GS20X models.

• The GS20X drive must be installed in a clean, well-ventilated and dry location, free from
corrosive gases or liquids.

• The GS20X drive must be stored within an ambient temperature range from –40°C to +85°C,
and relative humidity range of 0% to 90% without condensation.

• Do not apply AC power to the GS20X drive with the front cover removed. Following a fault of
the GS20X drive, wait 5 seconds before pressing the RESET key.

• To improve power factor, install a line reactor ahead of the GS20X drive. Do not install
power correction capacitors in the main AC supply circuit to the GS20X drive to prevent drive
faults due to over-current.

Wiring Diagrams

RFI Jumper Removal

If the power distribution system supplying the GS20X AC drive is a floating (IT) or an
asymmetric ground system, the RFI jumper must be removed.
Removing the RFI jumper uncouples the internal RFI capacitor (filter capacitor)
between the GS20X drive frame and circuitry to avoid damaging those circuits and
(according to IEC 61800-3) to reduce ground leakage current.

GS20X Frame A through C

Note: Rotate down

Main Wiring (Power Circuit)

For main (power) wiring terminal specifications, Please refer to “Specifications for Wiring Terminals –
Main-Circuit Terminals” (page 2).

GS20X all Frames

*(Note that 1-phase drives do not have a T/L3 terminal)

GS20X Control Terminal Wiring

FWD (DI1)

REV (DI2)

DI7

DCM

FWD (DI1)

REV (DI2)

DI7

DCM

Minimum Wiring

• AC input power to R/L1, S/L2, T/L3 (for single-phase input, use two of the terminals) (For applicability of 1-phase
input power, please refer to Chapter 1 of the DURApulse GS20X AC Drives User Manual at AutomationDirect.

com.)

• Ground from the power supply

• Drive power to the motor (U, V, W on T1, T2, T3) (For use with 3-phase motors only!)

• Ground to the motor

• STO1 and STO2 (both must be wired through appropriate N.C. safety-rated contacts to DCM or the
factory-installed jumpers must be left in place)

With this minimal wiring, the drive can be operated via the keypad to test the motor and drive installation.
See the “Parameter Set Up” (page 4) section to configure the drive for keypad operation.

Recommended Safety Wiring

We strongly recommend that customers use the STO safety feature.

The Safe Torque Off (STO) function turns off the power supplied to the motor through the hardware, so
that the motor cannot produce torque. This method of removing power from the motor is considered an
emergency stop, also known as “coast to stop.”

To use this feature, disconnect the appropriate factory-installed jumpers and wire a safety relay, safety PLC, or
E-Stop pushbutton as shown. See Main Wiring (Power Circuit) (page 1) for wiring the GS20X.

GS20X_QSP_1edRevA 10/19/2020

FWD (DI1)

REV (DI2)

DI7

DCM

FWD (DI1)

REV (DI2)

DI7

DCM

DURApulse GS20X AC Drive Quick-Start Guide – 1st EdRevA 10/19/2020

Page 1

DURApulse GS20X NEMA 4X AC Drive Quick-Start Guide

P02.00 External Terminal Control Circuits

Setting value: 1

Two-wire operation control
FWD / STOP
REV / STOP

Setting value: 2

Two-wire operation control
RUN / STOP
FWD / REV

Setting value: 3

Three-wire operation control

Specifications for Wiring Terminals – Control Circuit

GS20X-xxxx All Models; All Frame Sizes

Terminal Wire Gauge Torque

Control

Relay

24–18 AWG

[0.21–0.82 mm2]

24–16 AWG

[0.21–1.31 mm2]

FWD/DI1

REV/DI2

DCM

FWD/DI1

REV/DI2

DCM

FWD/DI1

DI3

REV/DI2

DCM

n/a (spring terminals)

5kg·cm

[4.3 lb·in]

GS20(X)

GS20(X)

GS20(X)

Recommended models or dimensions for ferrule terminals

Wire Gauge Manufacturer Model Name A (MAX) B (MAX) D (MAX) W (MAX)

0.25 mm2
[24 AWG]

0.34 mm2
[22 AWG]

0.5 mm2

[20 AWG]

PHOENIX
CONTACT

PHOENIX
CONTACT

PHOENIX
CONTACT

Z+F V30AE000006 14 8 2.6 1.15

AI 0,25- 8 YE 12.5 8 2.6 1.1

AI 0,34- 8 TQ 12.5 8 3.3 1.3

AI 0,5 - 8 WH 14 8 3.5 1.4

Specifications for Wiring Terminals – Main-Circuit Terminals

Notes:

• If you install at Ta 40°C above environment, please use copper wire with a 600V voltage rating and
temperature resistance of 90°C or higher.

• For UL compliant installation, you must:

1) Use 75°C temperature resistant copper wire or better. Do not reduce wire gauge when using higher
temperature wire.

2) Use the specific ring lug part listed in the table below.

3) Use crimp tool KST2000D-1322 or IZUMI 5N18 for 22–8 AWG wire, or
IZUMI 9H-60 for 6–4 AWG wire.

Specifications for Wiring Terminals – Main-Circuit Terminals (continued)

Drive Models

GS23X-27P5

GS23X-47P5

Frame C

GS23X-4010

Max Wire

Gauge

8AWG

[10 mm2]

Min Wire

Gauge

8AWG

[10 mm2]

10AWG

[6 mm2]

8AWG

[10 mm2]

RNBS

8-4

RNBS

5-4

RNBS

8-4

Screw

M4

Torque
(±10%)

20 kg-cm

[17,4 lb-in.]

[1.96 N·m]

Ring Lug Dimensions (mm)

Dimension Value Min/Max

A 17.8 Max

B 5.0 Max

C 6.1 Min

D 7.2 Max

d2 4.3 Min

E 13.0 Min

F 5.5 Min

W 8.0 Max

t 1.2 Max

PNP

AI2

DI6

4-20mA

0-20mA

SG+

AO1

DI7

SG-

NPN

SGND

DO1

+24V

DO2

+24V

DOC

USB

DATAMATRIX

24P

32637012

SLOT 1

RELAY

R1

R1C

R1O

RS485

Port

DO

DCM

DCM

4-20mA

0-20mA

AI2

+24V

Safety function

+10V

REV

FWD

0-10V

STO1

DI3

STO2

ACM

DI4

0-10V

AO1

SCM

AI1

DI5

Wiring Precautions

1) The factory default condition is +24 V/ S1/ S2 shorted by jumper, as shown in the block 1 of the figure above.
Refer to the wiring chapter of the User Manual for more details.

2) The +24 V power supply for safety function is only for STO use and cannot be used for other purposes.

3) The RELAY terminal uses the PCB terminal block:

• Tighten the wiring with a 3.5 mm width and 0.6 mm thickness slotted screwdriver.

• The ideal length of stripped wire at the connection side is 6–7 mm.

• When wiring bare wires, make sure they are perfectly arranged to go through the wiring holes.

4) The control circuit terminal uses a spring clamp terminal block:

• Tighten the wiring with a 2.5 mm width and 0.4 mm thickness slotted screwdriver.

• The ideal length of stripped wire at the connection side is 9 mm.

Drive Models

GS21X-20P5

GS21X-21P0

GS23X-20P5

GS23X-21P0

GS23X-40P5

GS23X-41P0

Frame A

GS21X-22P0

GS23X-22P0

GS23X-42P0

GS23X-43P0

GS21X-23P0

GS23X-23P0

Frame B

GS23X-25P0

GS23X-45P0

Max Wire

Gauge

12AWG
[4mm2]

14AWG

[2.5 mm2]

10AWG

[6 mm2]

12AWG
[4mm2]

10AWG

[6 mm2]

8AWG

[10 mm2]

Min Wire

Gauge

14AWG

[2.5 mm2]

12AWG
[4mm2]

18AWG

[0.75 mm2]

16AWG

[1.5 mm2]

18AWG

[0.75 mm2]

10AWG

[6 mm2]

14AWG

[2.5 mm2]

16AWG

[1.5 mm2]

14AWG

[2.5 mm2]

10AWG

[6 mm2]

8AWG

[10 mm2]

12AWG
[4mm2]

Ring

Lug P/N

RNBS

2-4

RNBS

5-4

RNBS

1-4

RNBS

5-4

RNBS

2-4

RNBS

1-4

RNBS

2-4

RNBS

5-4

RNBS

8-4

RNBS

5-4

Screw

M4

M3.5

M4

M4

M4

M4

Torque
(±10%)

15 kg-cm

[13.0 lb-in.]

[1.47 N·m]

9 kg-cm
[7.8 lb-in.]
[0.88 N·m]

20 kg-cm

[17.4 lb-in.]

[1.96 N·m]

15 kg-cm

[13.0 lb-in.]

[1.47 N·m

20 kg-cm

[17.4 lb-in.]

[1.96 N·m]

20 kg-cm

[17.4 lb-in.]

[1.96 N·m]

Ring Lug Dimensions (mm)

Dim. Value

14-18 AWG: 11.1

A

10-12 AWG: 12.1

B 4.0 Max

14-18 AWG: 6.3

C

10-12 AWG: 6.1

16-18 AWG: 3.4

D

14AWG: 4.1

10-12 AWG: 5.6

d2 4.3 Min

E 13.0 Min

16-18 AWG: 4.5

F

10-14 AWG: 5.5

14-18 AWG: 6.6

W

10-12 AWG: 7.2

14-18 AWG: 0.8

t

10-12 AWG: 1

Dimension Value Min/Max

A 17.8 Max

B 5.0 Max

C 6.1 Min

D 7.2 Max

d2 4.3 Min

E 13.0 Min

F 5.5 Min

W 8.0 Max

t 1.2 Max

Min/
Max

Max

Min

Max

Min

Max

Max

GS20X_QSP_1edRevA 10/19/2020

DURApulse GS20X AC Drive Quick-Start Guide – 1st EdRevA 10/19/2020

Page 2