Table of Contents
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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
compatibility: .....................................................................4
for purposes of EMC ........................................................4
2.4 Dimensions ......................................................................7
2.5 Template dimensions .......................................................8
2.6 Installation ........................................................................8
2.7 General description gfw ...................................................9
2.8 Cleaning/checking or replacing the fan .........................10
2.9 Replacing the Internal Fuse (Optional) .........................11
2.10 Card insertion for fieldbus interface ...............................12
(for biphase or triphase configuration) ..........................13
3 • ELECTRICAL CONNECTIONS3.1 ............................. ..14
3.1 Power connections.........................................................14
3.2 Functions of indicator leds ............................................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.
80962H_MHW_GFW_03-2021_ENG
GFW 40...300A
MODULAR POWER CONTROLLER
INDEX
GRAPHIC SYMBOLS
INSTALLATION AND
OPERATION MANUAL
Versione software: 2.1x
code 80962GH - 03-2021 - ENG
3.3 Description Input/Output ...........................................16
3.4 Connector J1 outputs 5...10 .........................................17
3.5 Connector J2 power supply ...........................................20
3.6 Connector J2 digital input ..............................................20
3.7 Connector J3 auxiliary inputs 5...8 ................................21
3.8 Connector J5 analog input control.................................22
3.9 Connctor J6: PID Input ..................................................23
3.10 Description of dip-switches ............................................24
3.11 Serial communication ports ...........................................25
3.12 Connection example: Power section .............................31
3.14 Trigger modes ................................................................39
3.15 Digital input (PWM) ........................................................43
4.1 "AUTOBAUD SERIAL 1" sequence ..............................45
5 • TECHNICAL CHARACTERISTICS ...............................46
5.1 Derating Curves .............................................................50
6 • COMMERCIAL INFORMATION ....................................51
6.1 Order code ....................................................................51
6.2 Accessories ....................................................................54
6.3 Fuses Extrarapid ............................................................54
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 40
Summary of Contents for gefran GFW 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 GEFRAN’s Technical Personnel that could be Indicates contents of sections, general instructions, notes, and especially useful under certain circumstances. -
Page 2: Preliminary Instructions
Soft Start ramp functions can be assigned to these controls, In particular, this new line of Gefran solid state relays is the with options such as “current limit” that keeps current peaks at ideal solution for sectors demanding high performance and power-on and RMS current level at full power under control. -
Page 3: Preliminary Instruction
See paragraph “ Dimensions and mounting” before installing the reliminary instruction GFW on the machine/host system control panel. Read the following preliminary instructions before To configure the PC use the SW Gefran GF-Express kit and the installing and using the GFX4-IR modular power relative connection cable. controller. -
Page 4: Installation And Connection
2 • INSTALLATION AND CONNECTION This section contains the instructions needed for ecommenDations for orrect nstallation correct installation of GFW modular power controller for PurPoses of on the machine/host system control panel and for correct connection of the power supply, inputs, 2.3.1 Instrument power supply outputs and interfaces. - Page 5 Snubber circuit to protect the thyristor). so that the air can flow vertically without any obstacles. GEFRAN S.p.A. assumes no liability for any • dissipation of device thermal power with effects on installation damage to persons or property deriving room temperature.
- Page 6 INSULATION DIAGRAM 80962H_MHW_GFW_03-2021_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) 80962H_MHW_GFW_03-2021_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 Line / load voltage connector 11 Control input connector “Line” terminals 12 Address Rotary Switch Configuration keypad connector 13 input connector PID Output connector 14 RJ10 connector serial RS485 (PORT 1) Supply connector 15 Dip Switch serial line (PORT 1) Digital input connector 16 Connector board Fieldbus (PORT 2) 4 input TCAUX connector... -
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: Replacing The Internal Fuse (Optional)
WARNING: the washer must stay between the nut and the fuse (NOT under the fuse). - Fasten the two nuts by the 3-4 Nm torque tube-shaped spanner N. 13 (GFW 40...150) ,tube-shaped spanner N17 (GFW 200...300 A) - Replace the cover pointing it to the lower part (pay attention to the connection tooth) -
Page 12: Card Insertion For Fieldbus Interface
2.10 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. -
Page 13: Connection Of Expansion Modules (For Biphase Or Triphase Configuration)
2.11 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 14: Electrical Connections3.1
3 • ELECTRICAL CONNECTIONS ower connections GFW 40...300 A RECOMMENDED WIRE GAUGES TIGHTENING / GFW CURRENT LEVEL TERMINAL WIRE GAUGE TERMINAL TYPE TOOL TORQUE Wire stripped for 25 mm or with 10 mm 5 Nm / Flat-head screwdriver 40 A... - Page 15 Leds State LED status refers to the corresponding parameter, with the following special cases: - LED RN (green) on: hotkey functionality - LED RN (green) + LED ER (red) both flashing rapidly: autobaud in progress - LED ER (red) on: error in one of main inputs (Lo, Hi, Err, Sbr) - LED ER (red) flashing: temperature alarm ((OVER_HEAT or TEMPERATURE_SENSOR_BROKEN) or alarm of SHORT_CIRCUIT_CURRENT or SSR_SAFETY or FUSE_OPEN (only for singlephase configuration). - LED ER (red) + LED Ox (yellow) both flashing: HB alarm or POWER_FAIL in zone x - All LEDs flashing rapidly: ROTATION123 alarm (only for threephase configuration) - All LEDs flashing rapidly except LED DI1: jumper configuration not provided - All LEDs flashing rapidly except LED DI2: 30%_UNBALANCED_ERROR alarm (only for threephase configuration)
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Page 16: Description Input/Output
escriPtion nPut utPut Figure 11 Top View Protection (Ref. V_load) 4 / T2 3 / L2 (Ref. V_line) J 10 Line / load voltage 1 / L1 connector “Line” Connection 1 / L1 “Line” Connection GFW-OP COM (OUT 5 - 8) keypad OUT 5 connector... -
Page 17: Connector J1 Outputs 5
5...10 onnector outPuts If auxiliary outputs (O5...O8), are present, connector J1a becomes J1. Figure 12 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 18 When using the continuous “C” output option, voltage or current is set using jumper links on the board (Figure 14 refers). Figure 14 Connection for logic/continuous utputs Internal OUT - C board (optional) Voltage settings Current settings OUT – C Board OUT –...
- Page 19 Outputs 5...8 triac type Triac outputs Vac = 24...230Vac, max 1A Figure 15 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 20: Connector J2 Power Supply
onnector Power suPPly Figure 18 Table 11 0,2 - 2,5mm 24-14AWG 0,25 - 2,5mm 23-14AWG Figure 19 Table 12 Decription Name +24 Vdc 24V Supply EARTH Ground EMC onnector DiGital inPut Figure 20 Table 13 0,14 - 0,5mm 28-20AWG 0,25 - 0,5mm 23-20AWG see paragraph “(PWM) digital input”... -
Page 21: Connector J3 Auxiliary Inputs 5
5...8 onnector auxiliary inPuts Figure 22 Table 15 0,14 - 0,5mm 28-20AWG 0,25 - 0,5mm 23-20AWG Figure 23 Auxiliary inputs I5 - I8 (60mV/TC) Table 16 Name Description Auxiliary input 2 Auxiliary input 3 Auxiliary input 4 Auxiliary input 5 80962H_MHW_GFW_03-2021_ENG... -
Page 22: Connector J5 Analog Input Control
onnector analoG inPut control Figure 24 Table 17 0,2 - 2,5mm 24-14AWG 0,25 - 2,5mm 23-14AWG Figure 25 Connection scheme Table 18 Name Description +5V_Out Supply output 5V potentiometer Control voltage Input SHUNT Shunt for input mA GND control signal 80962H_MHW_GFW_03-2021_ENG... -
Page 23: Connctor J6: Pid Input
J6: PiD i onnctor nPut Figure 26 Table 19 0,2 - 2,5mm 24-14AWG 0,25 - 2,5mm 23-14AWG Figure 27 Connection scheme for 60mV TC/linear input Figure 28 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,... -
Page 24: Description Of Dip-Switches
3.10 escriPtion of DiP switches Figure 30 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 25: Serial Communication Ports
3.11 erial communication Ports Port1 (local bus): Modbus serial interface – connectors S1, S2. Figure 31 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 26 Port2 (fieldbus): connectors S4, S5 MODBUS RTU/MODBUS RTU Figure 32 Port2: Fieldbus Modbus RTU/Modbus RTU interface 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.
- Page 27 Port2 (fieldbus): connectors S4, S5 MODBUS RTU/Profibus DP Figure 33 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 28 Port2 (fieldbus): connectors S4, S5 MODBUS RTU/CANopen Figure 34 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+)
- Page 29 Port2 (fieldbus): connectors S4, S5 Modbus RTU / Ethernet Modbus TCP Figure 35 Port2: Modbus RTU / Ethernet Modbus TCP interface S5 female connector S4 female connector 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+)
- Page 30 Port2 (fieldbus): connectors S4, S5 Modbus RTU / Ethernet IP or Modbus RTU / EtherCAT Figure 36 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.
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Page 31: Connection Example: Power Section
3.12 onnection examPle ower section Figure 37 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... - Page 32 Figure 39 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...
- Page 33 Figure 40 Sample GFW biphase connection for a triphase star load without neutral (*) Only required with Vload measurement input option. - FIRING MODE: ZC, BF - HB DIAGNOSTIC AVAILABLE: Total load failure FAST FUSE: needed only for controller with option Fuse = 0 GG Fuse: See Fuse section V = line voltage GFW Master - Dip-Switches Configuration...
- Page 34 Figure 42 Sample GFW biphase connection for a triphase closed delta load (*) Only required with Vload measurement input option. V = line voltage - FIRING MODE: ZC, BF GFW Master - Dip switch configuration P = total power Id = load current Dip 1 Dip 2 Dip 3...
- Page 35 Figure 44 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...
- Page 36 Figure 46 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...
- Page 37 Figure 48 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 - HB DIAGNOSTIC AVAILABLE: Vd= load voltage Partial and total load failure of each single leg P = total power Dip 1...
- Page 38 Figure 50 GFW connection example for 3 independent loads in open delta, 3-phase line without neutral (*) Only required with Vload measurement input option. - FIRING MODE: ZC, BF, HSC, PA - HB DIAGNOSTIC AVAILABLE: Partial and total load failure V= line voltage GFW Master - Dip-Switches Configuration of each single leg...
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Page 39: 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 40 Figure 53 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 41 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 42 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 58 Transient with Transient without Over-Current...
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Page 43: 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 44: Installation Of "Modbus" Serial Network
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 45: 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 46: 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 47 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 48 GFW 40 Nominal current 40Arms @40°C in continuous service Non-repetitive overcurrent t=10ms: 1400A I²t for blowout: 10000A²s GFW 60 Nominal current 60Arms @40°C in continuous service Non-repetitive overcurrent t=10ms: 1500A I²t for blowout: 12000A²s GFW 100 Nominal current 100Arms @40°C in continuous service Non-repetitive overcurrent t=10ms: 1900A I²t for blowout: 18000A²s...
- Page 49 Alarm masking Exclusion at power-on, latch, reset from digital input Totalizer of energy value supplied to load with local display by Energy calculation terminal and remote acquisition from fieldbus. Counters can be reset. OPTIONS - Timed Soft-Start firing ramp, with or without peak current control - Soft-Start firing ramp, specific for infrared lamps Options...
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Page 50: Derating Curves
2,6 kg 5,0 kg 7,4 kg Packaging dimension master/expansion model 2PH or 3PH 310x170x225 mm 410x355x260 mm eratinG urves Figure 61 GFW 40 / 60 / 100A GFW 150 / 200 / 250 / 300A I(A) I(A) T(C°) T(C°) 80962H_MHW_GFW_03-2021_ENG... -
Page 51: Commercial Information
(**) Option not available for models with Nominal Current <=300A (***) In case of replacement and/or insert of version E6, E7 in net using previous version of Fieldbus [ “E2” or “E4”] PLC SW will be recompiled, with its own file GSDML and ESD (****) To check the compatibility between the different product releases please look at the specific technical documentation on the web site www.gefran.com. 80962H_MHW_GFW_03-2021_ENG... -
Page 52: Accessories
(see EN60439-1, par. 7.5 “Short-circuit protection and short-circuit with stand strength” and 7.6 “Switching devices and components installed in assemblies”, otherwise the equivalent EN61439-1 paragraphs) GEFRAN spa via Sebina, 74 - 25050 Provaglio d’Iseo (BS) Tel. 03098881 - fax 0309839063 - Internet: http://www.gefran.com...