Gefran 40B96 User Guide

40B96

POSITION, FORCE and PRESSURE INDICATOR-INTERCEPTOR with INPUT

for STRAIN-GAUGE and POTENTIOMETER

Software Version 3.2x

code 81652D / Edit. 04 - 04/05

INSTRUCTIONS FOR USE
AND WARNINGS

GENERAL INDEX

30

page

Graphic symbol used 31

1 Preliminary instructions 31

General description 31
Alarm unit in basic version 31
Options 32
Operator interface 32
Electrical interface 32
Preliminary warnings 32

2 Installation and connection 33

Electrical power supply 33
Notes concerning electrical safety and
Electromagnetic compatibility 33
Advice for correct installation
for EMC 34
Instrument power supply 34
Inputs and outputs connection 34
Dimensions and cut-out 35
Installation with panel mounting 35
Warnings and instructions for
mounting to the panel 35
Nominal ambient conditions 35
Electrical connections 36
Example of connection with input from
Melt Sensor 38

3 Functions 39

Operator interface 39
General operating notes 40
Navigating through the instrument menu 41

page

4 Configuration and programming 42

Configuration/Programming 42

Application notes 50
Eb function 50
HOLD function 50
FLASH function 50
Alarms 50
Filter 51
UCAL strain-gauge calibration 51
Virtual Instrument 52

5 Technical specifications 53

6 Maintenance 54

Cleaning the instrument 54
Repairs 54
Checking the jumpers 54
Troubleshooting Guide 55

7 Technical-Commercial information 55

Order code 55

Accessories

RS232/TTL interface for Gefran
Instrument configuration 56

Appendix 56

The contents of each section are summarized
immediately following the section heading

Graphic symbols used

To distinguish between the type and importance of the information provided in these instructions for use, graphic

symbols have been used as a reference to make interpreting the information clearer .

Indicates the contents of the various manual sections,

the general warnings, notes, and other points to

which the reader's attention should be drawn.

Indicates a particularly delicate situation that

could affect the safety and correct working

operation of the instrument, or a rule that must

be strictly observed to avoid dangerous situa-

tions

Indicates a condition of risk for the safety of the

user, due to the presence of dangerous voltages

at the points shown

Indicates a suggestion based on the expe-

rience of the GEFRAN Technical Staff,

which could prove especially useful under

given circumstances

In the programming and configuration flows

for the controller, indicates all the parame-

ters that can be set in the configuration.

AL.2

1 • PRELIMINARY INSTRUCTIONS

This section contains information and warnings
of a general nature which should be read befo­re proceeding with instrument installation,
configuration and use.

General Description

GEFRAN series 40B96 digital controllers have been
designed for temperature control in any applications
involving heating or cooling processes. They represent
an exclusive combination of performance, reliability and
applicational flexibility. In particular, this new line of
Gefran temperature controllers is the ideal solution for
application in sectors where performance and service
continuity are important, including:

• extrusion lines

• presses for rubber

• test benches

• honing machines

• processing plant for the food industry

• weighing

• manostat

• positioner

• motopotentiometer

• etc.

The 40B96 series interceptors are made on an extremely
versatile hardware and software platform, that allows the
most suitable I/O composition for the plant to be chosen
from a series of options, up to a maximum of:

- variable input

- digital input

- transmitter power supply

- analog retransmission output

- a maximum of 4 outputs

- RS485 interface

Alarm unit in basic version

- 1 input that allows connection of most popular sensor

types

• potentiometer with 100 ohm minimum resistance

• load cells with autoranging sensitivity from 1.5 to 3.3
mV/V

• strain-gauge pressure probes
accuracy better than 0.2% f.s.

- output for sensor or transmitter power supply

• 1.2 Vdc for potentiometer

• 5Vdc, 10Vdc max 120 mA for strain-gauge

• 15Vdc, 24Vdc max 50 mA for transmitter

- 2 standard outputs: one relay type and the other
relay/logic, or

1 triac output

- display functions with setting of engineering scale

and possible linearization, settable decimal point
position, sampling time from 30 to 120 msec

- trip point values can be set in a range dif fering from
scale limits, different modalities, hysteresis settable in
scale points or time, with or without latch.

- service serial line for configuration via PC (Winstrum)

31

Options

- 3rd relay output

- 4th relay output (alternative to analog retransmission

output)

- 1 digital input

- 1 analog retransmission output in current

0/4…20mA or voltage 0…10V (alternative to 4th relay
output)

- RS485 optically isolated serial interface

Operator Interface

All the operator interface devices are concentrated on

the controller faceplate, suitably protected by a

membrane in Lexan that guarantees IP65 level

protection.

• 3 buttons to be used for manual configuration/selection

• 1 red five-digit displays (Process Variable)

• 4 red LEDs for status indication of same number of

relay/logic outputs

Electrical Interface

All connection terminals (power supply, inputs, outputs,

options) are grouped together on the back of the instru-

ment.

For technical specifications and performance details

refer to Section 5 "Technical Specifications”.

Preliminary Warnings

The following preliminary warnings should be
read before installing and using the series 40B
96 interceptor . This will allow the controller to
be put into service more quickly and will avoid
certain problems which may mistakenly be inter­preted as malfunctions or limitations of the inter­ceptor.

• Immediately after unpacking the controller, make a
note of the order code and the other identification data
given on the label affixed to the outside of the container
and copy them to the table below.
These details must always be kept close at hand and
referred to the personnel involved in the event of help
from Gefran Customer Service Assistance.

• Check also that the controller is complete and has
not been damaged at all during transit, and that the
package contains not only the instrument and these
Instructions for Use, but also the two brackets for
fixing to the panel and the dust protection seal - see:
Installation with Panel Fixing in Section 2.

Any inconsistencies, omissions or evident signs of
damage should be reported immediately to your
Gefran sales agent.

• Check that the order code corresponds with the
configuration requested for the application the
controller is needed for, referring to Section 7:
“Technical - Commercial Information”.

• No. and Type of Inputs/Outputs available

• Presence of the necessary options and

accessories

• Mains voltage supply

Ex: 40B – 24 – RR – 00 – 1 – 2 – 1

Model 40B96 alarm unit
24 V output for transmitter power supply
Output 1 - Relay; Output 2 - Relay,
Output 3 - none
Digital Input - no analog retransmission
RS485 Digital Communication
Power supply 100...240Vac/dc

• Before installing the series 40B96 instrument on
the control panel of the machine or host system, refer
to the paragraph "Dimensions and Cut-out" in
Section 2 "Installation and Connection”.

• Where configuration by PC is provided for, make sure
the interface RS232 cable is available and the
CD- ROM containing the WINSTRUM software.

For the order code refer to Section 7 "Technical ­Commercial Information”..

32

SN: ......................... (Serial no.)

CODE: ......................... (Finished product code)

TYPE: ......................... (Order Code)

SUPPLY: ......................... (Type of electrical power supply)

VERS: ......................... (Software version)

2 • INSTALLATION AND CONNECTION

This section contains the instructions necessary
for correct installation of the 40B96 instrument
into the machine control panel or the host
system and for correct connection of the inter­ceptor power supply, inputs, outputs and interfa­ces.

Before proceeding with installation read the
following warnings carefully!
Remember that lack of observation of these
warnings could lead to problems of electrical
safety and electromagnetic compatibility, as
well as invalidating the warranty.

Electrical power supply

• the instrument is NOT equipped with an On/Off switch:
the user must provide a two-phase disconnecting switch
that conforms to the required safety standards (CE mar­king), to cut off the power supply upstream of the instru­ment.
The switch must be located in the immediate vicinity of
the instrument and must be within easy reach of the ope­rator.
One switch may control more than one instrument.

• if the instrument is connected to NOT isolated electri­cal equipment (e.g. thermocouples), the earth connec­tion must be made with a specific conductor to prevent
the connection itself from coming directly through the
machine structure.

• if the instrument is used in applications with risk of
damage to persons, machinery or materials, it is essen­tial to connect it up to auxiliary alarm equipment.
It is advisable to make sure that alarm signals are also
triggered during normal operation.
The instrument must NOT be installed in flammable or
explosive environments; it may be connected to equip­ment operating in such atmospheres only by means of
appropriate and adequate types of interface, conforming
to the applicable safety standards.

Notes Concerning Electrical Safety and
Electromagnetic Compatibility:

CE MARKING: EMC Conformity (electromagnetic
compatibility)

in accordance with EEC Directive 89/336/CEE modified
by Directive 93/68.
Series 40B96 interceptor are mainly designed to opera­te in industrial environments, installed on the switch­boards or control panels of productive process machi­nes or plants.
As regards electromagnetic compatibility, the strictest
generic standards have been adopted, as indicated in
the table below.
BT Conformity (low tension) in accordance with
Directive 73/23/CEE modified by Directive 93/68.

EMC conformity has been tested with the following
connections.

Function Cable type Length

Power supply cable 1mm

2

1m

Relay output cables 1mm

2

3.5m

Serial connection wire 0,35mm

2

3.5m

Input 1mm

2

3m

33

34

Generic standards, emission standard for residential commer­cial and light industrial environments
Emission enclosure
Emission AC mains
Radiated emission

CEI EN 61000-6-3

CEI EN 61000-6-3
CEI EN 61000-6-3
CEI EN 61326 CISPR 16-2

Gruppo1 Classe B
Gruppo1 Classe B
Classe B

EMC Emission

EMC Immunity

Generic standards, immunity standard for industrial environ­ments
Immunity ESD

Immunity RF interference

Immunity conducted disturbance

Immunity burst

Immunity pulse

Immunity Magnetic fields
Voltage dips, short interruptions and voltage immunity tests

CEI EN 61000-6-2

CEI EN 61000-4-2

CEI EN 61000-4-3 /A1

CEI EN 61000-4-6

CEI EN 61000-4-4

CEI EN 61000-4-5

CEI EN 61000-4-8
CEI EN 61000-4-11

4 kV contact discharge level 2
8 kV air discharge
level 3
10 V/m amplitude modulated
80 MHz-1 GHz
10 V/m amplitude modulated

1.4 GHz-2 GHz
10 V/m amplitude modulated

0.15 MHz­80 MHz (level 3)
2 kV power line (level 3)
2 kV I/O signal line (level 4)
Power line-line 1 kV (level 2)
Power line-earth 2 kV (level 3)
Signal line-earth 1 kV (level 2)
100 A/m (level 5)
100%U, 70%U, 40%U,

LVD Safety

Safety requirements for electrical equipment for measurement,
control and laboratory use

CEI EN 61010-1

Advice for Correct Installation for EMC

Instrument power supply

• The power supply to the electronic equipment on the

switchboards must always come directly from an

isolation device with a fuse for the instrument part.

• The electronic instruments and electromechanical

power devices such as relays, contactors, solenoid

valves, etc., must always be powered by separate

lines.

• When the electronic instrument power supply is

strongly disturbed by the commutation of transistor or

power units or motors, an isolation transformer

should be used for the controllers only, earthing the

screen.

• It is essential that the plant has a good earth

connection:

- the voltage between neutral and earth must not be <1V

- the Ohmic resistance must be <6Ω;

• If the mains voltage fluctuates strongly, use a voltage

stabilizer.

• In the proximity of high frequency generators or arc

welders, use adequate mains filters.

• The power supply lines must be separate from the

instrument input and output ones.

Inputs and outputs connection

• The externally connected circuits must be doubly

isolated.

• To connect the analogue inputs the following is

necessary:

- physically separate the input cables from those of the

power supply, the outputs and the power connections.

- use woven and screened cables, with the screen

earthed in one point only

• To connect the regulating and alarm outputs

(contactors, solenoid valves, motors, fans, etc.), fit

RC groups (resistance and condensers in series) in

parallel to the inductive loads that operate in

Alternating Current.

(Note: all the condensers must conform to VDE

(class X2) standards and withstand a voltage of at

least 220V AC. The resistances must be at least 2W).

• Fit a 1N4007 diode in parallel with the coil of the

inductive loads that operate in Direct Current.

GEFRAN S.p.A. declines all responsibility for

any damage to persons or property caused

by tampering, neglect, improper use or any

use which does not conform to the characte-

ristics of the instrument and to the indica-

tions given in these Instructions for Use.

Dimensions and cut-out

Installation with panel mounting

As well as the actual instrument and these instructions

for use, the package also contains:

• 2 panel fixing brackets (A)

• 1 protective seal against dust and water spray ( B)

Fit the instrument to the panel as shown in the figure.

Warnings and instructions for mounting to the panel

Instructions for installation category II,

pollution level 2, double isolation.

• only for low power supply: supply from Class 2 or
low voltage limited energy source.

• the power supply lines must be separate from the
controller input and output ones

• group the instruments together keeping them
separate from the powered part of the relay

• do not install high-power remote switches,
contactors, relays, thyristor power units (especially
the "phase angle" type), motors, etc. in the same
switchboard

• avoid dust, humidity, corrosive gasses and heat
sources

• do not block the ventilation holes: the working
temperature must be between 0...50°C

• surrounding air: 50°C

• use 60/75°C copper (Cu) conductor only, wire size
range 2x No 22 - 14AWG, Solid/Stranded

• use terminal tightening torque 0.5N m

Nominal ambient conditions

Before supplying the Controller with power,
make sure that the mains voltage is the
same as that shown in the last number of
the order code.

Ex:
40B96-5 – xx – xx – xx – x – x – 1 = 100..240V ac/dc
40B96-5 – xx – xx – xx – x – x – 0 = 11..27Vac/dc

A

B

A

B

Altitude Up to 2000m
Working/storage 0..50°C/-20...70°C
temperature
Non condensing 20...85%
relative humidity

35

A

108

96

48

44,5

92

105

115

70

10

Electrical Connections

PWR

Outputs Out1 - Out2 - Out3

Inputs

Serial line

Digital
inputs

Output Out4 /

Retransm. Output

Always make the connections using cable types suitable for the voltage and current limits given in

Section 5 - Technical Specifications.

If the instrument has faston terminals these must be protected and isolated.

If it has screw terminals, the wires must be attached, at least in pairs

Power Supply

Inputs

Standard: 100...240V ac/dc ±10%
Optional: 1 1...27Vac7dc ±10%
Power: max 8VA; 50/60 Hz

Potentiometer input

4-wires strain gauge input

PWR

36

strain-gauge

24V

- IN

+ IN

+

-

-

+

+S

-S

Input for 0...20/4...20mA transmitter

Terminal 2 (IN -) can
be connected to
terminal 4 in case of
3-wire transmitter

1,2V

+

- IN

+ IN

~
~

Pot

- E

+ E

- IN

+ IN

+-

Inputs

Strain gauge input 6 wires to
connect to Melt transducers

Outputs Out1, Out 2, Out3 User configurable generic outputs

- Relay
5A cosϕ = 1
250Vac/30Vdc

- Triac

20...240Vac,
max. 1A ± 10%

Outputs Out 1

- Relay
5A cosϕ = 1
250Vac/30Vdc

- Logic 24V
10V a 20mA

Outputs Out 2

(absent on Out1 and of Triac type)

Outputs Out 3

Outputs Out 4 / Retransmission output User configurable generic outputs

- Relay 5A cosϕ = 1 250Vac/30Vdc

- Analogue 0...10V, 0/4...20mA

- 0/2...10V (S1-ON), 0/4...20mA (S1-OFF)
S1 is a jumper on the board for continuous or analogic output

Digital inputs User configurable generic inputs

- Digital input 24V 5mA (Jumpers S1, S2 in position P) or from non-powered terminal

(Jumpers S1, S2 in position N)
Hrd Menù configuration: Parameter diG or di2 = +16

Serial line

RS485 isolated serial line

Modbus 2 wires (Standard)

RS485 isolated serial line

For Modbus 4 wires/Cencal
configuration see technical
sheet of the serial board.

Modbus 4 wires / Cencal

37

strain-gauge

Brown or
Orange

Green

White

Black or
Yellow

Red

Blue

* For internal calibration

- Relay
5A cosϕ = 1
250Vac/30Vdc

S1

S1
S2

NP

12

*

13

-

E

+

E

- INS

+ IN

S

CAL

CAL

+-

NO

C

NO +

C -

NO

C

C

-

+

NO

-

+

GND

B
(data -)

A
(data +)

+

Rx

+

Tx

Example of Connection with Input from Melt Sensor

Analog retransmission of pressure value, logic and relay alarm outputs

38