gefran GPC 40-600A Use And Installation Manual
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gefran GPC 40-600A Use And Installation Manual

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GPC 40-600A
Advanced Power Controllers
USE AND INSTALLATION MANUAL
code: 81900A

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Summary of Contents for gefran GPC 40-600A

  • Page 1 GPC 40-600A Advanced Power Controllers USE AND INSTALLATION MANUAL code: 81900A...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents ............. 1 3.4.4. PORT2 (optional Fieldbus) type P: Modbus RTU / Profibus DP - connectors S4, S5 .......28 Preface ..............3 3.4.5. PORT2 (optional Fieldbus) type C: Modbus RTU / CANopen - connectors S4, S5 ........29 Device data and initial checks ............3 3.4.6.
  • Page 4 3.7.5. Connection example for two-phase GPC (2PH) for a three-phase star load without neutral with transformer . 3.7.6. Connection example for two-phase GPC (2PH) for a three-phase closed delta load ........61 3.7.7. Connection example for two-phase GPC (2PH) for a three-phase closed delta load with transformer ..62 3.7.8.

  • Page 5: Preface

    Gefran Technical Service, it is advisable to in the annexes as Gefran cannot be held liable for damage read the Troubleshooting Guide in the “Maintenance” sec- to persons, property and/or the product through failure to tion and the F.A.Q.

  • Page 6: Typographical Conventions Used In The Manual

    This calls the reader’s attention to a specific point. Liability disclaimer Although all information contained within this document Gefran S.p.A. cannot be held in any way liable for damage has been carefully checked, Gefran S.p.A. cannot be held to persons or property resulting from tampering or use that...

  • Page 7: General Description

    GENERAL DESCRIPTION 1.1. Summary 1.1.1. Profile Some functions of the GPC range are designed for specific applications and problems: The Advanced Power Controllers of the GPC series are • For systems with three-phase transformers, any self-contained units with the capability of controlling high breakages of three-phase load branches are man- electrical power levels for various types of single-phase, aged by the controller, which provides an immediate...

  • Page 8: Configuration

    The GF_eXpress configuration software (freely download- 1.1.6. More able from the Gefran site www.gefran.com) has a “Smart The availability of phase angle (PA) control (the only control Configuration” procedure to configure the controller through method that completely eliminates flickering in IR lamps),...

  • Page 9: Gpc-M

    1.4. GPC-M Main features • Single/two/three-phase, 40 A to 600 A • Operating voltages 480 Vac, 600 Vac and 690 Vac • Firing mode configurable to “Zero crossing” (Fixed Cy- cle, Burst Firing, Half Single Cycle) and “Phase angle” • Analogue control inputs configurable to Volt, mA, po- tentiometer and digital “PWM”...

  • Page 10: Main Elements Of The Gpc-M, 400 A

    1.4.2. Main elements of the GPC-M, 400 A ... 600 A models Figure 2 - Elements of the GPC-M 400 A ... 600 A models Auxiliary output connector 10. Protective cover on internal fuse and line/load connec- Relay output connector tions Power supply connector and 24 V digital inputs 11.

  • Page 11: Configuration Dip Switches

    1.6. Configuration dip switches • DIP switch 6: loading of the default values for the The DIP switches are used to set the configura- tion of the Advanced Power Controller. configuration selected with DIP switches 1 to 7. See paragraph “1.6.2. Initialisation procedure and loading The functions associated with the DIP switches of default values”...

  • Page 12: Led Indicator Functions

    1.7. LED indicator functions Colour Description green Run: flashing during regular operation Error status: activated in the presence of an alarm yellow Digital input 1 status yellow Digital input 2 status yellow Out 1 Master module (M) power output status yellow Out 2 expansion 1 (E1) power output status, managed only with GPC versions 2PH and 3PH yellow...

  • Page 13: Dimensions

    1.8. Dimensions 1.8.1. Dimensions of GPC, 40 A ... 300 A models Single-phase Side view with keypad Side view without keypad All dimensions in mm Figure 3 - Dimensions of GPC-M 40 ... 300 A (single-phase) Two-phase and Three-phase All dimensions in mm Figure 4 - Dimensions of GPC 40 ...

  • Page 14: Dimensions Of Gpc, 400 A

    1.8.2. Dimensions of GPC, 400 A ... 600 A Single-phase All dimensions in mm Figure 5 - Dimensions of GPC-M 400 ... 600 A (single-phase) Two-phase All dimensions in mm Figure 6 - Dimensions of GPC 400 ... 600 A (two-phase) 81900A “MHW_GPC-40/600A”_03-2021_ENG_page 12...
  • Page 15 (Three-phase) All dimensions in mm Figure 7 - Dimensions of GPC 400 ... 600 A (three-phase) 81900A “MHW_GPC-40/600A”_03-2021_ENG_page 13...

  • Page 16: Installation And Power Supply

    Gefran deal- this manual. er or Gefran Customer Service. Before installation, check that the controller is intact and has not been damaged during trans- port.
  • Page 17 Hot zone Outgoing air > 10 mm > 10 mm flow Air deflector Incoming air flow Cold zone Figure 8 - GPC minimum ventilation spaces Single-phase (1 PH) Two-phase (2 PH) Three-phase (3 PH) 87.2 87.2 87.2 4 holes 6 holes 4 holes 31.5 31.5...

  • Page 18: Power Supply

    2.2. Power supply The Advanced Power Controller is NOT supplied with an Ensure that the earth connection is efficient and made via ON/OFF switch. a specific conductor. A missing or ineffective earth connec- It is the responsibility of the user to provide a switch or tion can cause unstable device operation due to excessive disconnector compliant with the applicable safety re- environmental disturbances.
  • Page 19 EMC emission: AC semiconductor motor controllers and conductors for EN 60947-4-3 non-motor loads EN 60947-4-3 Emission enclosure compliant in firing mode single cycle and CISPR-11 Class A Group 2 phase angle if external filter fitted EN 55011 Table 1 EMC Immunity Generic standards, immunity standard for industrial environ- EN 60947-4-3 ments...

  • Page 20: Gpc Insulation Diagram

    2.5. GPC insulation diagram 81900A “MHW_GPC-40/600A”_03-2021_ENG_page 18...

  • Page 21: Electrical Connections

    ELECTRICAL CONNECTIONS CAUTION! Before connecting or disconnecting any connections, check that the power, power supply and con- trol cables are isolated from voltage. External circuits connected must have double insulation. The input cables must be physically separated from those of the power supply, outputs and power connections. Use braided and shielded cables for the inputs, with the sheathing earthed at a single point.
  • Page 22 Description of the GPC 400 A...GPC 600 A connections TOP VIEW BOTTOM VIEW Protective EARTH connection Connector V-LINE 2-T1 Connector (optional) Output connection 3 EXTERNAL CT inputs “LOAD” (bar or cable) 4/L2 3/L1 (Ref. V_LINE) TA1 + TA1 - KEYPAD connector TA2 + Connector (optional) TA2 -...

  • Page 23: Inputs

    3.2. Inputs 3.2.1. J3 connector - Power supply and digital inputs. The J3 connector includes the power input of the GPC controller and 4 digital inputs, configurable via software as NPN or PNP. For permissible voltages and currents see the Technical Data. Use cables with a cross-section of 0.25...2.5 mm2 (23-14 AWG) terminated with ferrules for connection.

  • Page 24: J4 Connector - Analogue Control Inputs

    3.2.2. J4 Connector - Analogue control inputs The J4 connector includes 3 analogue inputs, configurable via software as: • Voltage input 0...10 V • Voltage input 0...5 V • Potentiometer input • Current input 0...20 mA • Current input 4...20 mA For technical specifications, see the Technical Data.

  • Page 25: J5 Connector - External Ct Inputs (Optional)

    3.2.3. J5 connector - External CT inputs (optional) The J5 connector is only present if the product is equipped with control option 4, which has 3 external CT inputs. For technical specifications, see the Technical Data. Use shielded cables with a cross-section of 0.25...2.5 mm2 (23-14 AWG) terminated with ferrules for connection. Name Description TA1+...

  • Page 26: Outputs

    3.3. Outputs 3.3.1. J1 connector - outputs 5...8 (optional) The J1 connector is only present if the product is equipped with the optional auxiliary outputs (O5...O8). The available outputs can be relay type (R), digital type (D) or analogue type (W). For technical specifications, see the Technical Data.

  • Page 27: Optional Outputs Type W (Analogue)

    3.3.1.2. Optional outputs type W (analogue) Name Description Com 5-8 Common outputs Output 5 (+) Output 6 (+) Output 7 (+) Not used Option W includes 3 analogue 12-bit outputs configurable via software in: • Voltage 0...10 V • Voltage 2...10 V •...

  • Page 28: Serial Communication Port

    Name Description C (Out 9) Common contact of OUT9 OUT 9 NC (Out 9) Normally closed contact of OUT9 NO (Out 9) Normally open contact of OUT9 C (Out 10) Common contact of OUT10 NC (Out 10) Normally closed contact of OUT10 OUT 10 NO (Out 10) Normally open contact of OUT10 Figure 19 - Outputs 9 and 10 connection diagram...

  • Page 29: Port1 (Local Bus): Modbus Serial Interface - Connectors J8 And J9

    3.4.2. PORT1 (local bus): Modbus serial interface - connectors J8 and J9 Port fitted as standard on all GPC family. RS-485 Modbus RTU serial interface, J8 and J9 connectors and DIP switch for line termination. J8/J9 connector Name Description Cable type RJ10 4-4 plug GND1 * Flat telephone cable for 28AWG...

  • Page 30: Port2 (Optional Fieldbus) Type P: Modbus Rtu

    3.4.4. PORT2 (optional Fieldbus) type P: Modbus RTU / Profibus DP - connectors S4, S5 Port only present on GPC controllers with Fieldbus option Port 2 = P. RS-485 Modbus RTU / Profibus DP serial interface, S4 and S5 connectors and Profibus communication status LED. S5 female connector S4 female connector Green LED...

  • Page 31: Port2 (Optional Fieldbus) Type C: Modbus Rtu

    3.4.5. PORT2 (optional Fieldbus) type C: Modbus RTU / CANopen - connectors S4, S5 Port only present on GPC controllers with Fieldbus option Port 2 = C. RS-485 Modbus RTU / CANopen serial interface, S4 and S5 connectors and CANopen communication status LED. S5 male connector S4 female connector Red LED...

  • Page 32: Port2 (Optional Fieldbus) Type E: Modbus Rtu

    3.4.6. PORT2 (optional Fieldbus) type E: Modbus RTU / Ethernet Modbus TCP - connec- tors S4, S5 Port only present on GPC controllers with Fieldbus option Port 2 = E. RS-485 Modbus RTU / Ethernet Modbus TCP serial interface, S4 and S5 connectors and status LEDs on CPU front panel. S5 female connector S4 female connector Cable connector for...

  • Page 33: Port2 (Optional Fieldbus) Type E6 / E7 / E8 - Connec

    3.4.7. PORT2 (optional Fieldbus) type E6 / E7 / E8 - connectors S4, S5 Port only present on GPC controllers with the following options: • Fieldbus Port 2 = E6 for Modbus RTU / Profinet serial interface. • Fieldbus Port 2 = E7 for Modbus RTU / EtherCAT serial interface. •...

  • Page 34: Power Connections

    3.5. Power connections 3.5.1. Recommended cable cross-section with GPC 40 A ... 300 A CABLE TYPE/ GPC CUR- CABLE/BAR TERMINATION TERMINAL CROSS-SECTION BAR TIGHTENING TORQUE / TOOL FIG. RENT LEVEL TYPE TYPE/CROSS-SECTION Wire stripped for 25 mm or with crimped insulated end 40 A 1/L1, 2/T1 10 mm...

  • Page 35: Recommended Cable Cross-Section With Gpc 400 A

    3.5.2. Recommended cable cross-section with GPC 400 A ... 600 A CABLE TYPE/ GPC CUR- CABLE/BAR TERMINATION TERMINAL CROSS-SECTION BAR TIGHTENING TORQUE / TOOL FIG. RENT LEVEL TYPE TYPE/CROSS-SECTION x1 Bolt M12x25mm UNI 5739 Single cable, 300 mm Cable crimped to Cembre No.
  • Page 36 Fig. A Fig. B Snap line Bottom Bottom Fig. C Fig. D Snap line Bottom Bottom Fig. E Fig. F Bottom Fig. G Fig. H Snap line Bottom Bottom 81900A “MHW_GPC-40/600A”_03-2021_ENG_page 34...

  • Page 37: Connection Examples - Power Section For Gpc 40 A

    3.6. Connection examples - Power section for GPC 40 A...GPC 300 A 3.6.1. Connection example for single-phase GPC (1PH) for a single-phase load L2/N FUSE GG FUSE FUSE GG FUSE Id = V × cosφ 1/L1 1/L1 GPC-M 2/T1 GPC-M GG FUSE 2/T1 L2/N...

  • Page 38: Connection Example For Single-Phase Gpc (1Ph) For A Single-Phase Load With Transformer

    3.6.2. Connection example for single-phase GPC (1PH) for a single-phase load with transformer L2/N Id = ƞ × V × cosφ FUSE GG FUSE FUSE GG FUSE 1/L1 Is = × cosφ load 1/L1 GPC-M 2/T1 Vload GPC-M GG FUSE GG FUSE 2/T1 L2/N...

  • Page 39: Connection Example For Single-Phase Gpc (1Ph) Control Option 4 For Single-Phase Load With Transformer

    3.6.3. Connection example for single-phase GPC (1PH) control option 4 for single-phase load with transformer L2/N Id = ƞ × V × cosφ FUSE GG FUSE FUSE GG FUSE Input (J5) 1/L1 to TA1 Is = × cosφ load 1/L1 GPC-M 2/T1 load...

  • Page 40: Connection Example For Two-Phase Gpc (2Ph) For 2 Independent Single-Phase Loads

    3.6.4. Connection example for two-phase GPC (2PH) for 2 independent single-phase loads Two single-phase loads can also be connected to different supply lines, line to line or line and neutral. Different power levels can be managed for each of the two loads. Ly/N Ly/N x ≠...

  • Page 41: Connection Example For Two-Phase Gpc (2Ph) For A Three-Phase Star Load Without Neutral

    3.6.5. Connection example for two-phase GPC (2PH) for a three-phase star load without neutral FUSE FUSE FUSE FUSE FUSE 1/L1 1/L1 GPC-E1 FUSE 1/L1 2/T1 GPC-M FUSE 2/T1 1/L1 GPC-E1 GPC-M 2/T1 2/T1 GG FUSE Id = √ 3 × V × cos φ GPC - DIP switch configuration DIP 1 DIP 2...
  • Page 42 3.6.6. Connection example for two-phase GPC (2PH) for a three-phase star load without neutral with transformer FUSE FUSE FUSE FUSE FUSE FUSE 1/L1 Symmetric transformers only Y - Y Δ - Δ 1/L1 1/L1 GPC-E1 FUSE 2/T1 1/L1 load GPC-M FUSE 2/T1 1/L1...

  • Page 43: Connection Example For Two-Phase Gpc (2Ph) Control Option 4 For A Three-Phase Star Load Without Neutral With Transformer

    3.6.7. Connection example for two-phase GPC (2PH) control option 4 for a three-phase star load without neutral with transformer FUSE FUSE FUSE FUSE FUSE FUSE TA1…TA2 1/L1 Input (J5) Symmetric transformers only to TA2 to TA1 Y - Y Δ - Δ 1/L1 1/L1 GPC-E1...

  • Page 44: Connection Example For Two-Phase Gpc (2Ph) For A Three-Phase Closed Delta Load

    3.6.8. Connection example for two-phase GPC (2PH) for a three-phase closed delta load FUSE FUSE FUSE FUSE 1/L1 1/L1 FUSE GPC-E1 FUSE 1/L1 2/T1 GPC-M FUSE GPC-E1 GPC-M 2/T1 1/L1 2/T1 2/T1 GG FUSE Id = Load Load √3 × V × cosφ Load GPC - DIP switch configuration DIP 1...

  • Page 45: Connection Example For Two-Phase Gpc (2Ph) For A Three-Phase Closed Delta Load With Transformer

    3.6.9. Connection example for two-phase GPC (2PH) for a three-phase closed delta load with transformer FUSE FUSE FUSE FUSE FUSE FUSE FUSE 1/L1 SYMMETRIC ASYMMETRIC transformers 1/L1 1/L1 GPC-E1 FUSE 2/T1 1/L1 load GPC-M FUSE 2/T1 1/L1 GPC-E1 GPC-M GG FUSE 2/T1 2/T1 Id =...

  • Page 46: Connection Example For Two-Phase Gpc (2Ph) Control Option 4 For A Closed Delta Load With Transformer

    3.6.10. Connection example for two-phase GPC (2PH) control option 4 for a closed delta load with transformer FUSE FUSE FUSE FUSE FUSE FUSE 1/L1 TA1…TA2 Input (J5) SYMMETRIC to TA2 to TA1 ASYMMETRIC transformers 1/L1 1/L1 GPC-E1 FUSE 2/T1 1/L1 load GPC-M FUSE...

  • Page 47: Connection Example For Three-Phase Gpc (3Ph) For 3 Independent Single-Phase Loads

    3.6.11. Connection example for three-phase GPC (3PH) for 3 independent single-phase loads Two single-phase loads can also be connected to different supply lines, line to line or line and neutral. Different power levels can be managed for each of the two loads. Ly/N Ly/N Ly/N...

  • Page 48: Connection Example For Three-Phase Gpc (3Ph) For A Three-Phase Star Load With Neutral

    3.6.12. Connection example for three-phase GPC (3PH) for a three-phase star load with neutral GPC-M FUSE FUSE FUSE FUSE GG FUSE 1/L1 2/T1 GPC-E1 FUSE 1/L1 2/T1 GPC-E2 FUSE 1/L1 1/L1 1/L1 1/L1 2/T1 GPC-E2 GPC-E1 GPC-M GG FUSE 2/T1 2/T1 2/T1 Vd =...

  • Page 49: Connection Example For Three-Phase Gpc (3Ph) For A Three-Phase Star Load Without Neutral

    3.6.13. Connection example for three-phase GPC (3PH) for a three-phase star load without neutral FUSE FUSE FUSE GPC-M FUSE 1/L1 2/T1 GPC-E1 FUSE 1/L1 1/L1 1/L1 2/T1 1/L1 GPC-E2 FUSE 2/T1 1/L1 GPC-E2 GPC-E1 GPC-M GG FUSE 2/T1 2/T1 2/T1 Vd = Id = √3...
  • Page 50 3.6.14. Connection example for three-phase GPC (3PH) for a three-phase star load without neutral with transformer GPC-M FUSE FUSE FUSE FUSE 2/T1 1/L1 SYMMETRIC ASYMMETRIC transformers 1/L1 1/L1 1/L1 GPC-E1 FUSE 2/T1 1/L1 load GPC-E2 FUSE 2/T1 1/L1 GPC-E2 GPC-E1 GPC-M 2/T1 2/T1...

  • Page 51: Connection Example For Three-Phase Gpc (3Ph) Control Option 4 For A Three-Phase Star Load Without Neutral With Transformer

    3.6.15. Connection example for three-phase GPC (3PH) control option 4 for a three-phase star load without neutral with transformer GPC-M FUSE FUSE FUSE FUSE 2/T1 1/L1 TA1, TA2, TA3 SYMMETRIC Input (J5) to TA3 to TA2 ASYMMETRIC to TA1 transformers GPC-E1 1/L1 1/L1...

  • Page 52: Connection Example For Three-Phase Gpc (3Ph) For Three-Phase Closed Delta Load

    3.6.16. Connection example for three-phase GPC (3PH) for three-phase closed delta load GPC-M FUSE 1/L1 2/T1 FUSE FUSE FUSE GPC-E1 FUSE 2/T1 1/L1 GPC-E2 FUSE 2/T1 1/L1 1/L1 1/L1 1/L1 Id = √3 × V × cosφ GPC-E2 GPC-E1 GPC-M GG FUSE 2/T1 2/T1...

  • Page 53: Connection Example For Three-Phase Gpc (3Ph) For A Three-Phase Closed Delta Load With Transformer

    3.6.17. Connection example for three-phase GPC (3PH) for a three-phase closed delta load with transformer GPC-M FUSE FUSE FUSE FUSE 1/L1 2/T1 SYMMETRIC ASYMMETRIC transformers GPC-E1 1/L1 1/L1 1/L1 FUSE 2/T1 load 1/L1 GPC-E2 FUSE 1/L1 2/T1 GPC-E2 GPC-E1 GPC-M GG FUSE 2/T1 2/T1...

  • Page 54: Connection Example For Three-Phase Gpc (3Ph) Control Option 4 For Three-Phase Closed Delta Load With Transformer

    3.6.18. Connection example for three-phase GPC (3PH) control option 4 for three-phase closed delta load with transformer GPC-M FUSE FUSE FUSE FUSE 2/T1 1/L1 TA1, TA2, TA3 SYMMETRIC Input (J5) to TA3 to TA2 ASYMMETRIC to TA1 transformers GPC-E1 1/L1 1/L1 1/L1 FUSE...

  • Page 55: Connection Example For Three-Phase Gpc (3Ph) For Three-Phase Open Delta Load

    3.6.19. Connection example for three-phase GPC (3PH) for three-phase open delta load FUSE FUSE FUSE GPC-M 1/L1 2/T1 FUSE GG FUSE FUSE FUSE FUSE GG FUSE 1/L1 1/L1 1/L1 1/L1 2/T1 2/T1 1/L1 GG FUSE GPC-E2 GPC-E1 GPC-M 2/T1 2/T1 2/T1 FUSE Id =...

  • Page 56: Connection Example For Three-Phase Gpc (3Ph) For 3 Independent Loads In Open Delta

    3.6.20. Connection example for three-phase GPC (3PH) for 3 independent loads in open delta GPC-M FUSE FUSE FUSE 1/L1 2/T1 FUSE GG FUSE FUSE FUSE FUSE GG FUSE 1/L1 1/L1 1/L1 1/L1 2/T1 2/T1 1/L1 GG FUSE GPC-E2 GPC-E1 GPC-M FUSE 2/T1 2/T1...

  • Page 57: Connection Examples - Power Section For Gpc 400 A

    3.7. Connection examples - Power section for GPC 400 A...600 A 3.7.1. Connection example for single-phase GPC (1PH) for a single-phase load L2/N FUSE GG FUSE FUSE FUSE (**) 1/L1 GPC-M 1/L1 2/T1 GG FUSE GPC-M 2/T1 L2/N GG FUSE Id = V ×...

  • Page 58: Connection Example For Single-Phase Gpc (1Ph) For A Single-Phase Load With Transformer

    3.7.2. Connection example for single-phase GPC (1PH) for a single-phase load with transformer L2/N FUSE GG FUSE FUSE FUSE 1/L1 (**) (***) GPC-M 1/L1 2/T1 load GPC-M GG FUSE 2/T1 (**) L2/N GG FUSE Load R Id = Is = ×...

  • Page 59: Connection Example For Two-Phase Gpc (2Ph) For 2 Independent Single-Phase Loads

    3.7.3. Connection example for two-phase GPC (2PH) for 2 independent single-phase loads Two single-phase loads can also be connected to different supply lines, line to line or line and neutral. Different power levels can be managed for each of the two loads. L /N L /N X = Y...

  • Page 60: Connection Example For Two-Phase Gpc (2Ph) For A Three-Phase Star Load Without Neutral

    3.7.4. Connection example for two-phase GPC (2PH) for a three-phase star load without neutral FUSE FUSE FUSE GG FUSE GG FUSE (**) GPC-E1 FUSE 2/T1 1/L1 GPC-M FUSE 1/L1 1/L1 2/T1 1/L1 Id = √3 × V × cos φ GPC-E1 GPC-M 2/T1...

  • Page 61: Connection Example For Two-Phase Gpc (2Ph) For A Three-Phase Star Load Without Neutral With Transformer

    3.7.5. Connection example for two-phase GPC (2PH) for a three-phase star load without neutral with transformer Control option = 0 Control option = 3 (Vload inputs) FUSE FUSE GG FUSE GG FUSE 1/L1 1/L1 1/L1 1/L1 GPC-E1 GPC-M GPC-E1 GPC-M 2/T1 2/T1 2/T1...
  • Page 62 Control option = 4 (Vload inputs and external CT inputs) FUSE GG FUSE TA1,TA2 input (J5) to TA1 to TA2 1/L1 1/L1 GPC-E1 GPC-M 2/T1 2/T1 GG FUSE Δ Symmetric transformers only Δ TA1 (to J5) Current Transformers Load Load Load GPC - DIP switch configuration DIP 1...

  • Page 63: Connection Example For Two-Phase Gpc (2Ph) For A Three-Phase Closed Delta Load

    3.7.6. Connection example for two-phase GPC (2PH) for a three-phase closed delta load FUSE GG FUSE GG FUSE (**) FUSE GPC-E1 FUSE 1/L1 2/T1 1/L1 1/L1 GPC-M FUSE 2/T1 1/L1 GPC-E1 GPC-M 2/T1 2/T1 Id = √3 × V × cos φ FUSE Load CAUTION...

  • Page 64: Connection Example For Two-Phase Gpc (2Ph) For A Three-Phase Closed Delta Load With Transformer

    3.7.7. Connection example for two-phase GPC (2PH) for a three-phase closed delta load with transformer Control option = 0 Control option = 3 (Vload inputs) FUSE FUSE GG FUSE GG FUSE 1/L1 1/L1 1/L1 1/L1 GPC-E1 GPC-M GPC-E1 GPC-M 2/T1 2/T1 2/T1 2/T1...
  • Page 65 Control option = 4 (Vload inputs and external CT inputs) FUSE GG FUSE TA1,TA2 input (J5) to TA1 to TA2 1/L1 1/L1 GPC-E1 GPC-M 2/T1 2/T1 GG FUSE Y/Δ Symmetric Y/Δ and asymmetric transformers. Recommended: ASYMMETRIC TA1 (to J5) Current Transformers R Load GPC - DIP switch configuration...

  • Page 66: Connection Example For Three-Phase Gpc (3Ph) For 3 Independent Single-Phase Loads

    3.7.8. Connection example for three-phase GPC (3PH) for 3 independent single-phase loads Three single-phase loads can also be connected to different supply lines, line to line or line and neutral. It is possible to manage different powers for each of the three loads from the Fieldbus.

  • Page 67: Connection Example For Three-Phase Gpc (3Ph) For A Three-Phase Star Load With Neutral

    3.7.9. Connection example for three-phase GPC (3PH) for a three-phase star load with neutral GPC-M FUSE FUSE 1/L1 2/T1 GG FUSE GPC-E1 FUSE (**) 1/L1 2/T1 GPC-E2 FUSE 2/T1 1/L1 1/L1 1/L1 1/L1 Vd = Id = √3 √3 × V × cos φ GPC-E2 GPC-E1 GPC-M...

  • Page 68: Connection Example For Three-Phase Gpc (3Ph) For A Three-Phase Star Load Without Neutral

    3.7.10. Connection example for three-phase GPC (3PH) for a three-phase star load without neutral FUSE GPC-M FUSE GG FUSE 1/L1 2/T1 (**) GPC-E1 FUSE 2/T1 1/L1 GPC-E2 FUSE 1/L1 1/L1 1/L1 2/T1 1/L1 Vd = Id = √3 × V × cos φ √3 GPC-E2 GPC-E1...

  • Page 69: Connection Example For Three-Phase Gpc (3Ph) For A Three-Phase Star Load Without Neutral With Transformer

    3.7.11. Connection example for three-phase GPC (3PH) for a three-phase star load without neutral with transformer Control option = 0 Control option = 3 (Vload inputs) FUSE FUSE GG FUSE GG FUSE 1/L1 1/L1 1/L1 1/L1 1/L1 1/L1 GPC-E2 GPC-E1 GPC-M GPC-E2 GPC-E1...
  • Page 70 Control option = 4 (Vload inputs and external CT inputs) FUSE GG FUSE TA1,TA2,TA3 input (J5) to TA1 to TA2 to TA3 1/L1 1/L1 1/L1 GPC-E2 GPC-E1 GPC-M 2/T1 2/T1 2/T1 GG FUSE Y/Δ Symmetric and asymmetric transformers Y/Δ Current transformers TA1 (to J5) Load Load...

  • Page 71: Connection Example For Three-Phase Gpc (3Ph) For Three-Phase Closed Delta Load

    3.7.12. Connection example for three-phase GPC (3PH) for three-phase closed delta load GPC-M FUSE 2/T1 1/L1 FUSE GPC-E1 FUSE 1/L1 2/T1 GG FUSE (**) GPC-E2 FUSE 2/T1 1/L1 1/L1 1/L1 1/L1 Id = √3 × V × cos φ GPC-E2 GPC-E1 GPC-M 2/T1...

  • Page 72: Connection Example For Three-Phase Gpc (3Ph) For A Three-Phase Closed Delta Load With Transformer

    3.7.13. Connection example for three-phase GPC (3PH) for a three-phase closed delta load with transformer Control option = 0 Control option = 3 (Vload inputs) FUSE FUSE GG FUSE GG FUSE 1/L1 1/L1 1/L1 1/L1 1/L1 1/L1 GPC-E2 GPC-E1 GPC-M GPC-E2 GPC-E1 GPC-M...
  • Page 73 Control option = 4 (Vload inputs and external CT inputs) FUSE GG FUSE TA1,TA2,TA3 imput (J5) to TA1 to TA2 to TA3 1/L1 1/L1 1/L1 GPC-E2 GPC-E1 GPC-M 2/T1 2/T1 2/T1 GG FUSE Symmetric Y/Δ and asymmetric transformers Y/Δ TA1 (to J5) Current transformers R Load GPC - DIP switch configuration...

  • Page 74: Connection Example For Three-Phase Gpc (3Ph) For Three-Phase Open Delta Load

    3.7.14. Connection example for three-phase GPC (3PH) for three-phase open delta load GPC-M 1/L1 2/T1 GG FUSE FUSE GG FUSE GG FUSE GG FUSE 1/L1 (**) 2/T1 2/T1 1/L1 1/L1 1/L1 1/L1 GG FUSE GPC-E2 GPC-E1 GPC-M 2/T1 2/T1 2/T1 3 ×...

  • Page 75: Connection Example For Three-Phase Gpc (3Ph) For 3 Independent Loads In Open Delta

    3.7.15. Connection example for three-phase GPC (3PH) for 3 independent loads in open delta GPC-M 1/L1 2/T1 GG FUSE FUSE GG FUSE GG FUSE GG FUSE 1/L1 (**) 2/T1 2/T1 1/L1 1/L1 1/L1 1/L1 GG FUSE Id = GPC-E2 GPC-E1 GPC-M V ×...

  • Page 76: Notes On Use With Inductive Loads And Transformers

    3.8. Notes on use with inductive loads and transformers • When the GPC controller is in operation, it is NOT permissible to disconnect the connection between the GPC and the transformer or between the transformer and the load. • The maximum current that can be controlled by the GPC is reduced compared to the nominal value of the device (see technical specifications).

  • Page 77: Operating Modes

    OPERATING MODES 4.1. Trigger modes For power control the Advanced Power Controller provides 20%, we will have conduction for 2 seconds (100 conduc- the following modes: tion cycles @ 50Hz) and non-conduction for 8 seconds (400 • modulation through variation of the number of conduc- non-conduction cycles @ 50Hz).

  • Page 78: Hsc - Half Single Cycle

    (Ton = 0.5 cycle) (Toff = 0.5 cycle) Toff Toff Figure 22 - Example of operation in HSC mode at 33% and 66% power 4.1.2. Phase angle (PA) 4.1.1.3. HSC - Half single cycle This mode corresponds to Burst Firing, which handles on/ This mode manages the power on the load by modulating off semi-cycles.

  • Page 79: Additional Functions

    4.2. Additional functions 4.2.1. Softstart 4.2.2. RMS current limit This type of start can be enabled either in phase control The option to control the load current limit is available in all mode or in zero-crossing mode (ZC, BF, HSC,PA). operating modes.

  • Page 80: Dt - Delay Triggering

    4.2.3. DT - Delay triggering The example in the figure compares the methods of starting The triggering delay (only for control modes ZC, BF) can be a transformer: Softstart ramp (for PA mode) and Delay trig- set from 0° to 90°. gering (for ZC and BF modes).

  • Page 81: Digital Input (Pwm)

    The signal can be generated by an external controller or NOTE: For INDIG2 and INDIG3 inputs, the maximum PWM external PLC via digital outputs (logic output for Gefran frequency is limited to 1 Hz. INDIG4, however, is not config- instruments).

  • Page 82: Using Port 1 "Modbus Rtu

    USING PORT 1 “MODBUS RTU” A network typically has a Master that “manages” communication by means of “commands,” and Slaves that carry out these commands. GPC should be considered as a Slave to the network Master, which is normal a supervisory terminal or a PLC. It is uniquely identified by a node address (ID) set on the rotary switches (tens + units).

  • Page 83: Maintenance

    MAINTENANCE Caution! Repairs to the Advanced Power Controller must only be made by technical personnel suitably trained and authorised by Gefran. Any attempt to repair or modify the hardware features of the device by unauthorised personnel will void the warranty.

  • Page 84: Replacing The Internal Fuse

    6.2. Replacing the internal fuse Caution! Disconnect the voltage before and during the fuse replacement procedure. The Advanced Power Controller is equipped with an internal There is no need to completely undo the nuts as the protection fuse (optional). fuse is removed from its housing by sliding it out, as The replacement procedure and equipment required varies indicated by the arrows.
  • Page 85 Procedure for replacing the internal fuse in GPC models CAUTION! The washer must be between the bolt and from 400 A to 600 A the copper strip (NOT under the fuse). Unscrew the fixing screw and remove the cover in the direction indicated by the arrow.

  • Page 86: Replacing The Fieldbus Interface Board

    6.3. Replacing the fieldbus interface board Caution! Disconnect the power supply before and Extract the Fieldbus interface board and insert the new during the board replacement procedure. one in the connectors provided on the support board. Check that the board is inserted correctly. Put the CPU cover back in place and secure it by tight- Caution! Use ESD protection devices to prevent ening the screws.

  • Page 87: Technical Specifications

    TECHNICAL SPECIFICATIONS INPUTS INA1, INA2, INA3 - Analogue control inputs Configurable Yes, via software Linear: 0...5 Vdc, Ri = 90 kΩ Voltage Power control % value Linear: 0...10 Vdc, Ri = 90 kΩ acquisition function Current Linear: 0/4…20 mA, Ri = 250 Ω Potentiometer 1...10 kΩ, 5 Vdc power supply max 30 mA from GPC Line frequency...
  • Page 88 OUTPUTS OUT1, OUT2, OUT3 - Heating outputs (connected directly to static units) Configurable Yes (default hot setting) Status display Via LED (O1, O2, O3) OUT1: GPC-M Function Connection OUT2: GPC-E1 OUT3: GPC-E2 OUT5...OUT8 - Auxiliary outputs (option) Function Configurable Number Type NO contact with single common Relay outputs (R)
  • Page 89 COMMUNICATION PORTS GPC-OP PORT Serial communication for GFW/GPC-OP terminal for parame- Function ter display/programming DOOR 1 (always present) Function Modbus serial communication Number Type RS-485 Port Insulation 1500 V Connector RJ10 4-4 telephone type Line termination DIP switch Node address Adjustable via rotary-switches Communication Protocol...
  • Page 90 POWER (Static Group) AC 51 resistive or low-inductance loads CATEGORY OF USE AC 55b short-wave infrared lamps (SWIR) (EN60947-4-3 Tab. 2) AC 56a transformers, high temperature coefficient resistive loads load management by adjusting the power-on phase angle Zero Crossing with constant cycle time (settable in the range 1...200 sec).
  • Page 91 Rated current: 40 Arms @ 40 °C in continuous service Non-repetitive overcurrent, t = 10 ms: 1400 A GPC 40 I²t for blowout: 10 000 A Rated current: 60 Arms @ 40 °C in continuous service Non-repetitive overcurrent, t = 10 ms: 1500 A GPC 60 I²t for blowout: 12 000 A Rated current: 100 Arms @ 40 °C in continuous service...
  • Page 92 FUNCTIONS • Timed softstart ramp, with or without peak current control. • Softstart ramp, specifically for infrared lamps. • Time-controlled switch-off ramp. • RMS load current limitation. • Delay-Triggering 0-90° for firing inductive loads in ZC General and BF mode. •...
  • Page 93 GENERAL DATA GPC 1PH/2PH/3PH Voltage: 24 VDC ±10% (models from 40 to 300 A) Power consumption: 25 max Voltage: 24 VDC ±10% GPC 1PH-400/500/600A Power consumption: 38 max Power supply Voltage: 24 VDC ±10% GPC 2PH-400/500/600A Power consumption: 66 max Voltage: 24 VDC ±10% GPC 3PH-400/500/600A Power consumption: 94 max...

  • Page 94: Derating Curves

    7.1. Derating curves GPC 40 A - GPC 60 A - GPC 100 A GPC 150 A - GPC 200 A - GPC 250 A - GPC 300 A I [A] I [A] T [°C] T [°C] GPC 400 A - GPC 500 A - GPC 600 A I [A] T [°C] 81900A “MHW_GPC-40/600A”_03-2021_ENG_page 92...

  • Page 95: Order Codes

    ORDER CODES Order code: GPC- -0-0- Model Fieldbus Port 2 Single-phase model (GPC-M) Absent Modbus RTU Two-phase model (GPC-M + GPC-E1) Profibus DP Three-phase module (GPC-M CANopen + GPC-E1/2) Modbus TCP Ethernet Profinet Rated current: EtherCAT 40 A Ethernet IP 60 A 100 A Fuse...

  • Page 96: Accessories

    ACCESSORIES 9.1. Kit, keypad and cables Code Description GF_eXpress software on CD-ROM, USB/485/TTL converter complete with cables for F049095 GF_eXK-2-0-0 connection to PC, Geflex, GTF, GFW and instrument. Programming panel for GFW/GPC Power Controllers. F068952 GFW/GPC-OP LCD display 5 lines x 21 characters, keypad for displaying and setting parameters. Attachment to GFW/GPC-M via magnetic plate.

  • Page 97: Short-Circuit Protection / Sccr

    9.4. Short-circuit protection / SCCR The products listed in the table are suitable for use in cir- Caution! The opening of the circuit protection cuits capable of supplying up to 100 000 RMS symmetrical device may indicate that it has been tripped by a amps, 600 V max if protected by fuses.
  • Page 98 81900A “MHW_GPC-40/600A”_03-2021_ENG_page 96...
  • Page 100 GEFRAN spa via Sebina, 74 25050 Provaglio d’Iseo (BS) Italy Tel. +39 0309888.1 Fax +39 0309839063 info@gefran.com http://www.gefran.com...

This manual is also suitable for:

81900a

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