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1 • PRELIMINARY INSTRUCTIONS �������������������������������������2
1.1 Profile �������������������������������������������������������������������������������2
1.2 General Description ���������������������������������������������������������2
1.3 Preliminary instruction ������������������������������������������������������3
2 • INSTALLATION AND CONNECTION ������������������������������4
2.1 Electrical power supply ����������������������������������������������������4
2.2 Notes on electrical safety and ������������������������������������
2.3 Recommendations for Correct Installation �����������������
2.4 Dimensions ����������������������������������������������������������������������7
2.6 Template dimensions �������������������������������������������������������8
2.5 Installation ������������������������������������������������������������������������8
2.7 General description gfw ���������������������������������������������������9
2.8 Cleaning/checking or replacing the fan �������������������������10
2.9 Card insertion for fieldbus interface ������������������������������� 11
2.10 Connection of expansion modules (for biphase or triphase
configuration) ��������������������������������������������������������������������������12
3 • ELECTRICAL CONNECTIONS �������������������������������������13
3.1 Power connections���������������������������������������������������������13
3.2 Functions of indicator leds ���������������������������������������������13
3.3 Description Input/Output �������������������������������������������14
To differentiate the type and importance of the information in this User Manual, graphic reference symbols are used to make such information
easier to interpret.
Indicates contents of sections, general instructions, notes, and
other points to which the reader's attention needs to be called.
Indicates a particularly delicate situation that could affect
the safety or correct operation of the controller, or an
instruction that MUST be followed to prevent hazards�
Indicates a risk to the user's safety due to high voltage at the
points indicated.
80993B_MHW_GFW-Xtra_06-2018_ENG
GFW-Xtra
MODULAR POWER CONTROLLER WITH OVERCURRENT FAULT PROTECTION
INDEX
GRAPHIC SYMBOLS
INSTALLATION AND
OPERATION MANUAL
Versione software: 2�1x
code 80993B - 06/2018 - ENG
3.5 Connector J2 power supply �������������������������������������������18
3.6 Connector J2 digital input ����������������������������������������������18
3.7 Connector J3 auxiliary inputs 5...8 ��������������������������������19
3.8 Connector J5 analog input control���������������������������������20
3.9 Connctor J6: PID Input ��������������������������������������������������21
3.10 Description of dip-switches ��������������������������������������������22
3.11 Serial communication ports �������������������������������������������23
3.12 Connection example: Power section �����������������������������29
3.14 Trigger modes ����������������������������������������������������������������36
3.15 Overcurrent Fault Protection Function �������������������������40
3.16 Digital input (PWM) ��������������������������������������������������������41
5 • TECHNICAL CHARACTERISTICS �������������������������������44
5.1 Derating Curves �������������������������������������������������������������47
6 • Commercial Information ����������������������������������������������48
6.1 Order code ���������������������������������������������������������������������48
6.2 Accessories ��������������������������������������������������������������������49
6.3 Fuses ������������������������������������������������������������������������������49
Indicates a suggestion based on the experience of
GEFRAN's Technical Personnel that could be
especially useful under certain circumstances.
Indicates a reference to Detailed Technical
Documents available on the GEFRAN website
www.gefran.com.
1
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Table of Contents
Related Manuals for gefran GFW-Xtra 40
Summary of Contents for gefran GFW-Xtra 40
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Page 1: Table Of Contents
To differentiate the type and importance of the information in this User Manual, graphic reference symbols are used to make such information easier to interpret. Indicates a suggestion based on the experience of Indicates contents of sections, general instructions, notes, and GEFRAN’s Technical Personnel that could be other points to which the reader’s attention needs to be called. especially useful under certain circumstances. Indicates a particularly delicate situation that could affect... -
Page 2: Preliminary Instructions
In particular, this new line of Gefran solid state relays is the fault protection function. ideal solution for sectors demanding high performance and... -
Page 3: Preliminary Instruction
GFW on the machine/host system control panel. installing and using the GFW modular power controller. To configure the PC use the SW Gefran GF-Express kit and the This will make start-up faster and avoid some relative connection cable. problems that could be mistakenly interpreted as For the order code, see Section “Technical-Commercial... -
Page 4: Installation And Connection
2 • INSTALLATION AND CONNECTION This section contains the instructions needed ecommenDations for orrect nstallation for correct installation of GFW modular power for PurPoses of controller on the machine/host system control panel and for correct connection of the power 2�3�1 Instrument power supply supply, inputs, outputs and interfaces. - Page 5 • thermal power dissipation with limits on installation room temperature. GEFRAN S.p.A. assumes no liability for any • requires exchange with external air or an air conditioner to damage to persons or property deriving from transfer dissipated power outside the panel.
- Page 6 INSULATION DIAGRAM 80993B_MHW_GFW-Xtra_06-2018_ENG...
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Page 7: Dimensions
imensions Figure 1 GFW MASTER Lateral view Lateral view with keypad without keypad GFW DUAL-PHASE GFW THREE-PHASE (Master + 1 Expansion) (Master + 2 Expansions) 80993B_MHW_GFW-Xtra_06-2018_ENG... -
Page 8: Template Dimensions
emPlate Dimensions Figure 2 PANEL MOUNTING AND CUT-OUT DIMENSIONS GFW MASTER GFW DUAL-PHASE GFW THREE-PHASE Fastening may be done with (5MA). All dimensions are expressed in mm. nstallation Figure 3 Attention: respect the minimum distances shown in figure 3 to provide adequate air circulation. -
Page 9: General Description Gfw
eneral DescriPtion Gfw Figure 4 11 Control input connector Line / load voltage connector 12 Address Rotary Switch “Line” terminals 13 input connector PID Configuration keypad connector Output connector 14 RJ10 connector serial RS485 (PORT 1) Supply connector 15 Dip Switch serial line (PORT 1) 16 Connector board Fieldbus (PORT 2) Digital input connector 17 Cooling Fan... -
Page 10: Cleaning/Checking Or Replacing The Fan
leaninG checkinG or rePlacinG the fan PERIODIC CLEANING Every 6-12 months (depending on the dust level of the installation) blow a compressed air jet downward through the upper rectangular cooling grilles (on the side opposite the fan). This will clean the internal heat dissipater and the cooling fan. IN CASE OF OVERHEAT ALARM If periodic cleaning does not eliminate the problem, do as follows: a Remove the fan support grille by detaching the two support tabs... -
Page 11: Card Insertion For Fieldbus Interface
arD insertion for fielDbus interface DO AS FOLLOWS: a. Undo the screws 16 b. Turn slightly the points18 using a screwdriver c. Remove the cover 17 d. Place the interface card 19 in the connectors prepared on card 21 e. Remove the pre-formed blanks parts 20 on cover 17 according to the type of interface installed f�... -
Page 12: Connection Of Expansion Modules
2.10 onnection of exPansion moDules for biPhase or triPhase confiGuration CARRY OUT THE FOLLOWING STEPS: a. Remove the master module side cover by undoing the fastening screws b Connect the flat cables supplied with the expansions to CPU card by inserting them into the appropriate connectors. c. -
Page 13: Electrical Connections
3 • ELECTRICAL CONNECTIONS ower connections GFW 40-100A RECOMMENDED WIRE GAUGES CURRENT TIGHTENING / TERMINAL WIRE GAUGE TERMINAL TYPE LEVEL TOOL TORQUE 10 mm Wire stripped for 25 mm or with crimped 5 Nm / Flat-head 1/L1, 2/T1 7 AWG pre-insulated terminal tube CEMBRE PKC1018 screwdriver tip 1 x 5.5 mm Wire stripped for 25 mm or with crimped 5 Nm / Flat-head... -
Page 14: Description Input/Output
escriPtion nPut utPut Figure 8 Top View Protection (Ref. V_load) 4 / T2 3 / L2 (Ref. V_line) J 10 Line / load voltage connector 1 / L1 “Line” Connection 1 / L1 “Line” Connection COM (OUT 5 - 8) GFW-OP OUT 5 keypad... -
Page 15: Connector J1 Outputs 5
5...10 onnector outPuts If auxiliary outputs (O5...O8), are present, connector J1a becomes J1. Figure 9 Connector J1 Table 6 0,2 - 2,5mm 24-14AWG 0,25 - 2,5mm 23-14AWG Outputs 5���8 logic/continuous type Logic outputs 18...36Vdc, max 20mA Continuous outputs: voltage (default) 0/2...10V, max 25mA current 0/4...20mA, max 500Ω... - Page 16 When using the continuous “C” output option, voltage or current is set using jumper links on the board (Figure 14 refers). Figure 11 Connection for logic/continuous utputs Internal OUT - C board (optional) Voltage settings Current settings OUT – C Board OUT – C Board 80993B_MHW_GFW-Xtra_06-2018_ENG...
- Page 17 Outputs 5���8 triac type Triac outputs Vac = 24...230Vac, max 1A Figure 12 Connection scheme for triac outputs Com 5÷8 Table 8 Name Decription Outputs common Com 5-8 Output 5 Output 6 Output 7 Output 8 Outputs 5���8 relay type Outputs Out 5...8 relay Ir = 3A max, NO V = 250V/30Vdc cos = 1;...
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Page 18: Connector J2 Power Supply
onnector Power suPPly Figure 15 Table 11 0,2 - 2,5mm 24-14AWG 0,25 - 2,5mm 23-14AWG Figure 16 Table 12 Name Decription +24 Vdc 24V Supply EARTH Ground EMC onnector DiGital inPut Figure 17 Table 13 0,14 - 0,5mm 28-20AWG 0,25 - 0,5mm 23-20AWG see paragraph “(PWM) digital input”... -
Page 19: Connector J3 Auxiliary Inputs 5
5...8 onnector auxiliary inPuts Figure 19 Table 15 0,14 - 0,5mm 28-20AWG 0,25 - 0,5mm 23-20AWG Figure 20 Auxiliary inputs I5 - I8 (60mV/TC) Table 16 Name Description Auxiliary input 2 Auxiliary input 3 Auxiliary input 4 Auxiliary input 5 80993B_MHW_GFW-Xtra_06-2018_ENG... -
Page 20: Connector J5 Analog Input Control
onnector analoG inPut control Figure 21 Table 17 0,2 - 2,5mm 24-14AWG 0,25 - 2,5mm 23-14AWG Figure 22 Connection scheme Table 18 Name Description +5V_Out Supply output 5V potentiometer Control voltage Input SHUNT Shunt for input mA GND control signal 80993B_MHW_GFW-Xtra_06-2018_ENG... -
Page 21: Connctor J6: Pid Input
J6: PiD i onnctor nPut Figure 23 Table 19 0,2 - 2,5mm 24-14AWG 0,25 - 2,5mm 23-14AWG Connection scheme for 60mV Figure 24 TC/linear input Figure 25 Connection scheme for Pt100 input Table 20 Name Description EARTH EMC earth (for shielded cable) Negative Input Positive Input TC and RTD 3rd Wire RTD, Positive IN mA, Connection scheme for 1V/20mA Figure 26... -
Page 22: Description Of Dip-Switches
3.10 escriPtion of DiP switches Figure 27 Table 22 Description dip-switches Connection type: (see table 23) Connection type: (see table 23) Connection type: (see table 23) Connection type: (see table 23) OFF = resistive load ON = inductive load (transformer primary control) ON = reset factory configuration ON = Geflex simulation function... -
Page 23: Serial Communication Ports
3.11 erial communication Ports Port1 (local bus): Modbus serial interface – connectors S1, S2� Figure 28 Table 24 Connector S1/S2 Nr� Pin Name Description Note RJ10 4-4 pin GND1 (**) (*) Insert the RS485 line termination in the last device Data reception/transmission (A+) Tx/Rx+ on the Modbus line, see dip-... - Page 24 Port2 (fieldbus): connectors S4, S5 MODBUS RTU/MODBUS RTU Port2: Fieldbus Modbus RTU/Modbus RTU interface Figure 29 Connector S5 Connector S4 Line termination (*) Table 25 Connector S4/S5 Nr� Pin Name Description Note RJ10 4-4 pin GND1 (**) (*) Insert the line termination in the last device on the Modbus line. Data reception/transmission (A+) Tx/Rx+ Data reception/transmission (B-)
- Page 25 Port2 (fieldbus): connectors S4, S5 MODBUS RTU/Profibus DP Figure 30 Port2: Fieldbus Modbus RTU/Profibus DP interface S5 female connector S4 female connector Yellow Led Red Led Green Led Table 26 Connector S4 Nr� Pin Name Description Note RJ10 4-4 pin GND1 (**) (**) Connect the GND signal between Modbus devices with a Data reception/transmission (A+) Rx/Tx+...
- Page 26 Port2 (fieldbus): connectors S4, S5 MODBUS RTU/CANopen Figure 31 Port2: Fieldbus Modbus RTU/CANOpen interface S5 male connector S4 female connector Red Led Green Led Table 28 Connector S4 Nr� Pin Name Description Note RJ10 4-4 pin GND1 (**) (**) Connect the GND signal between Modbus devices with a Rx/Tx+ Data reception/transmission (A+) line distance >...
- Page 27 Port2 (fieldbus): connectors S4, S5 Modbus RTU / Ethernet Modbus TCP Figure 32 Port2: Modbus RTU / Ethernet Modbus TCP interface S5 female connector S4 female connector Yellow Led Green Led Table 30 Connector S4 Nr� Pin Name Description Note RJ10 4-4 pin GND1 (**) (**) Connect the GND signal between Modbus devices with a Data reception/transmission (A+) Rx/Tx+...
- Page 28 Port2 (fieldbus): connectors S4, S5 Modbus RTU / Ethernet IP or Modbus RTU / EtherCAT Figure 33 Port2: Modbus RTU / Ethernet IP or Modbus RTU / EtherCAT Green led Packet activity Yellow led Link integrity S4 female connector S5 female connector Table 32 Connector S4 Nr� Pin Name Description Note RJ10 4-4 pin GND1 (**)
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Page 29: Connection Example: Power Section
3.12 onnection examPle ower section Figure 34 GFW connection example for 1 single-phase load (*) Only required with Vload measurement input option. V= phase voltage (line - neutral) - FIRING MODE: ZC, BF, HSC, PA GFW Master - Dip-Switches Configuration P = power of each single-phase load Id = load current - HB DIAGNOSTIC AVAILABLE: Partial and total load failure Dip 1... - Page 30 Figure 36 Sample GFW biphase connection for a triphase star load without neutral (*) Only required with Vload measurement input option. V = line voltage - FIRING MODE: ZC, BF P = total power GFW Master - Dip-Switches Configuration - HB DIAGNOSTIC AVAILABLE: Total load failure Id = load current Dip 1 Dip 2 Dip 3...
- Page 31 Figure 38 GFW connection example for 1 3-phase closed delta load (*) Only required with Vload measurement input option. - FIRING MODE: ZC, BF, PA (P >6%) V= line voltage - HB DIAGNOSTIC AVAILABLE: Partial and total load failure P = total power of each single leg Id = load current GFW Master - Dip-Switches Configuration - in PA mode, HB diagnostic active with P>30% if resistive load cosϕ=1...
- Page 32 Figure 40 GFW connection example for 1 3-phase star load without neutral (*) Only required with Vload measurement input option. - FIRING MODE: ZC, BF, PA (P >6%) V= line voltage - HB DIAGNOSTIC AVAILABLE: Partial and total load failure of Vd= load voltage each single leg P = total power GFW Master - Dip-Switches Configuration Id = load current - in PA mode, HB diagnostic active with P>30%...
- Page 33 Figure 42 GFW connection example for 1 3-phase star load with neutral Only required with Vload measurement input option. - FIRING MODE: ZC, BF, HSC, PA V= line voltage GFW Master - Dip-Switches Configuration Vd= load voltage - HB DIAGNOSTIC AVAILABLE: P = total power Dip 1 Dip 2 Dip 3 Dip 4 Dip 5...
- Page 34 Figure 44 GFW connection example for 3 independent loads in open delta, 3-phase line without neutral (*) Only required with Vload measurement input option. V= line voltage - FIRING MODE: ZC, BF, HSC, PA GFW Master - Dip-Switches Configuration P = power of each single-phase load - HB DIAGNOSTIC AVAILABLE: Partial and total load failure Id = load current Dip 1 Dip 2...
- Page 35 Figure 46 Example of GFW-2PH for 2 indipendent single phase loads It is possible to connect two single-phase loads also to different line voltages, between line to line or line to neutral It is possible to manage different power values for each one of the two loads. V= line voltage GFW Master - Dip-Switches Configuration P = power of each single-phase load Id = load current...
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Page 36: Trigger Modes
3.13 otes use with inDuctive loaDs anD transformers a) when the GFW is working it is not allowed to open neither the connection between GFW and the transformer nor the connection between the transformer and the load b) The maximum current controllable by the device is less than the product’s rated value (see technical data). c) In ZC and BF trigger mode, use the Delay-triggering function to limit peak magnetization current. - Page 37 Figure 48 parameter defines the minimum number of conduction cycles settable from 1 to 10. In the following example, the parameter = 2. HSC - Half single cycle This mode corresponds to Burst Firing that manages ON and OFF half-cycles. It is useful for reducing the flickering of filaments with short/medium-wave IR lamp loads.
- Page 38 ADDITIONAL FUNCTIONS Softstart This type of start can be enabled either in phase control or pulse train mode and in zero-crossing mode (ZC, BF, HSC). In phase control, the increment of conduction angle q stops at the corresponding value of the power to be transferred to the load.
- Page 39 DT - “Delay triggering” (for ZC, BF control modes only) Settable from 0° to 90°. Useful for inductive loads (transformer primaries) to prevent current peak that in certain cases could trip the high-speed fuses that protect the SCRs. Figure 53 Transient with Transient without Over-Current...
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Page 40: Overcurrent Fault Protection Function
3.15 vercurrent ault rotection unction Overcurrent fault protection function: it does not use a fuse of type extrafast for the protection of the controller . In case of short circuit of the load, the device is turned off instantly and is activated the corresponding alarm indication FUSE_OPEN; if configured (Fr.n different from zero), the load is switched on again for a maximum number of attempts Fr.n beyond which the device remains off waiting for the manual reset button through front BUT or via the serial command (bit 109). Number of restarts in case of FUSE_OPEN Fr. n 109* Reset alarms SHORT_CIRCUIT_CUR- OFF= - RENT E FUSE_OPEN ON = Reset alarms SHORT_CIRCUIT_CURRENT e FUSE_OPEN... -
Page 41: Digital Input (Pwm)
This digital input can be used to receive information on the % of power to be supplied to the load. The signal can be generated by a controller or external plc via digital outputs (logic output for Gefran instrumentation). This is obtained by alternating the output in ON for time TON with the output in OFF for time TOFF. -
Page 42: Installation Of "Modbus" Serial Network �42
4 • INSTALLATION OF “MODBUS” SERIAL NETWORK A network typically has a Master that “manages” communication by means of “commands,” and Slaves that carry out these commands. GFW modules is considered Slaves to the network master, which is usually a supervision terminal or a PLC. It is positively identified by means of a node address (ID) set on rotary switches (tens + units). -
Page 43: Autobaud Serial 1" Sequence
“autobauD serial 1” sequence Function Adapt the serial communication speed and parity of the GFW modules to the connected supervision terminal or PLC. Green LED L1 “STATUS” mentioned in the procedure can vary its behavior based on parameter Ld.1, which is set to a default value of 16. Procedure 1) Connect the serial cables for all modules on the network to serial 1 and to the supervision terminal. -
Page 44: Technical Characteristics
5 • TECHNICAL CHARACTERISTICS INPUTS INA Analogic control inputs Function Acquisition of % value for power control Linear: 0,…,5Vdc, Ri>100Kohm Voltage Linear: 0,…,10Vdc, Ri>100Kohm Current Linear: 0/4…20mA, Ri =125ohm Potentiometric 1, ..., 10Kohm, max 10mA from 5Vdc power GFW IN1 Analog process inputs (option) Function Acquisition of process variable Max. - Page 45 OUT5,���,OUT8 cooling control outputs (option) Function Configurable (default: cooling control) Relay Contact NO 3A, 250V/30Vdc cosφ =1 0/2…10V (default), max 25mA short circuit protection Continuous 0/4…20mA, max. load 500ohm isolation 500V Logic 24Vdc, > 18V a 20mA Triac 230V/ max 4A AC51 (1A for each channel) OUT9, OUT10 alarm Function Function Configurable (default alarms)
- Page 46 GFW 40 Nominal current 40Arms @40°C in continuous service GFW 60 Nominal current 60Arms @40°C in continuous service Rated current AC51 non-inductive or slightly inductive loads, resistance furnaces GFW 100 Nominal current 100Arms @40°C in continuous service NOTE (for all models) Minimum load controllable: 5 % of product current rated level.
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Page 47: Derating Curves
- with one Master unit: 1 single-phase load - with one Master units and one Expansion: 2 single-phase loads in ZC and BF trigger mode only: 1 phase load closed delta controlled on two phases Type of connection and load 1 phase load star without neutral controlled on two phases - with one Maste units and two Expansions: Selection via dip-switches... -
Page 48: Commercial Information
6 • COMMERCIAL INFORMATION rDer coDe GFW - Model FIELDBUS Port 2 opz� Module Mono-Phase (Master) Absent Module Dual-Phase Modbus RTU (Master + n. 1 expansion) Profibus DP Module Three-phase CANopen (Master + n. 2 Expansions) Ethernet Modbus TCP Ethernet IP Nominal Current EtherCAT 40 Ampere... -
Page 49: Accessories
ccessories CONFIGURATION KIT Configuration/supervision kit for GFW by means of PC with USB (Windows environment). KIT PC USB / RS485 o TTL Lets you read or write all of the parameters of a single GFW A single software for all models • Easy and rapid configuration • Saving and management of parameter recipes • On-line trend and saving of historical data Component Kit: - Connection cable PC USB <----> GFW RS485 port - Serial line converter - CD SW GF Express installation... - Page 50 Note 80993B_MHW_GFW-Xtra_06-2018_ENG...
- Page 51 80993B_MHW_GFW-Xtra_06-2018_ENG...
- Page 52 GEFRAN spa via Sebina, 74 - 25050 Provaglio d’Iseo (BS) Tel. 03098881 - fax 0309839063 - Internet: http://www.gefran.com...