Gefran GFX4-IR Data Sheet

Main application

• Thermoforming

• Blowing

• Hot runners for injection presses

• Fiber weaving

• Heat treatment furnaces

• Wood-working machines

• Glass hardening furnaces

GFX4-IR

4-ZONE MODULAR POWER CONTROLLER FOR IR LAMPS AND INDUCTIVE LOADS

Main features

Stand-alone unit for independent control of
four electrical power control loops.
Extremely compact, with independent controls
and advanced diagnostics. Used to control
power for single-phase and 3-phase loads,
including high and low temperature coefficient
resistive loads, short wave infrared lamps and
transformer primaries.

Unit consisting of:

• Controller

• 30, 60, 80kW solid state relay

• Current transformers

• Fuses-holder (option)

• 4 universal main inputs

• 4 heat/cool independent PID

• 4 main output internally wired to the SSR

• 4 auxiliary analog inputs (option)

• 4 configurable output (option):
relay / logic / TRIAC / continuous

• 2 configurable relay alarm output

• 2 digital inputs

• Standard digital communication:
Modbus RTU

• Optional Fieldbus communication:
Profibus DP, CANopen, Euromap66,
DeviceNet, Modbus RTU, Modbus TCP,

Ethernet IP, EtherCAT, ProfiNET

• DIN rail or panel mounting

PROFILE

GFX4-IR is a four independent loop
controller, designed to manage electrical
power.
GFX4 is a compact unit encompassing
technological elements such as:

• controller

• solid state relay

• current transformers

• fuses-holders (option)
The final result is a cost saving in terms
of space and cabling.
The GFX4-IR is managed by a micropro­cessor that independently controls the
four control loops and also runs functions
specifically designed to manage single­phase and 3-phase loads, with low and
high temperature coefficient, medium and
short wave infrared lamps, control single
phase and 3-phase transformers (exam­ple, with loads such as Super Kanthal or
silicon carbide).
The multiple activation methods are all
software-configurable, and include:

- Zero crossing with constant cycle time
for conventional loads

- Burst firing with variable cycle time for
systems with low thermal inertia,
medium wave IR lamps

- Semi-Cycle for short wave IR lamps
with reduced flickering (half single cycle)

- Phase angle control with current limit for
short wave IR lamps, transformer pri­maries, with assignment of soft start and
soft stop options with limitation of max.
rms current.

GFX4IR runs complete diagnostics of cur­rent, voltage, and temperature levels:

Current

- Total and partial interrupted load alarm

- Function for self-learning of alarm thres­ hold for interrupted load

- SCR in short circuit alarm

- Unbalanced 3-phase line alarm

- Unbalanced 3-phase load alarm

Voltage

- Phase loss in case of 3-phase
configurations

- Check of correct phase sequence alarm

Temperature

- Overtemperature alarm

For complete load control in all applica­tions, various feedback functions have
been developed:

- Voltage (V) feedback with maximum
voltage limit

- Current (I) feedback with maximum
current limit

- Power feedback with maximum power
limit
Configuration is changed by setting sim­ple parameters with a software tool that
guides the user to a correct and safe
configuration.
GFX4-IR communicates with the operator
terminals according to the most popular
protocols: from the simple and efficient
Modbus to (via a second optional fieldbus
communication) the by-now indispensa­ble Profibus DP, CANopen, DeviceNet,
Modbus RTU, Ethernet Modbus TCP,
Ethernet IP, EtherCAT, ProfiNET.
The product comes with a standard
configuration that is simple and quick to
modify, for example, to assign different
functions to outputs.

MODELS

(see table in order code)

3 different sizes, depending on the elec­tric power managed, are available.

GFX4-IR 80

Maximum contemporaneous power up to
80kW@480V.
Each zone can manage up to 19,2 kW.
This limit can be extend to 27,3 kW using
the “smart power management” (not all
the zone contemporaneous).
Nominal current 40A for zone, not con­temporary maximum 57A.

GFX4-IR 60

Maximum contemporaneous power up to
60kW@480V.
Each zone could reach up to 15,3 kW.
Nominal current 32A for zone (UL30A).
Fuse holder could be provide as an
option.

GFX4-IR 30

Maximum contemporaneous power up to
30kW@480V.
Each zone could reach up to 7,6 kW.
Nominal current 16A for zone. Fuse hol­der could be provide as an option.

INPUTS

Process analogue

4 universal process input can accept:

- thermocouple

- thermoresistance

- linear current & voltage.
Input type can be selected by software,
no external devices are required.

Digital

2 digital input.
The function can be selected from a wide
range, including setpoint selection, MAN/
AUTO, alarm memory reset and many
other.

Incorporated CT

Four CTs are integrated in the product to
control currents delivered to each zone
and to manage the related alarms (HB...).

Auxiliary analogue (option)

4 further analogue inputs are available,
typically for external current transformer
reading.

OUTPUTS

A current transformer is furnished with
TRIAC output.

Alarms

Two relay outputs are available, configu­rable as minimum or maximum alarms.

LEDs

Eight monitoring led are available in order
to provide diagnostic information.
RN RUN state of the CPU
ER error
DI1 DI1 digital input state
DI2 DI2 digital input state
O1 Output 1 state
O2 Output 2 state
O3 Output 3 state
O4 Output 4 state
By default a different meaning is applicable.

POWER

The solid-state power unit (SSR) is inte­grated in the product. The SSR is built
with 4 pairs of SCR in antiparallel.

Configurable start-up modes
ZC - Zero Crossing constant cycle time
(settable in range 1-200sec)
BF - Burst Firing variable cycle time
(GTT)
HSC - Half Single Cycle corresponds to
Burst Firing that manages single
semi-cycles of conduction or stop
cycles
Useful for reducing flicker with
short wave IR loads (applied only
to single-phase load or 3-phase
open delta 6 leads)
PA - Phase Angle that manages the
firing angle.

Load type:
4 single-phase
3 independent single-phase in open delta
1 3-phase open delta, 6 leads
1 3-phase delta, 3 leads
1 3-phase star without neutral, 3 leads
1 3-phase star with neutral, 4 leads

.

FUSES (option)

The fuses are orderable on the GFX4-IR
30KW and 60kW model.
Thanks to this, you save time, wiring is
simplified, and dimensions in the panel
are reduced.

FUNCTIONS

Control

The Geflex control algorithm works with
any type of thermal process.
Different control modes are available:
from a simple ON/OFF control to PID sin­gle or double acting heat/cool (for cooling,
simply indicate the fluid used).
Sophisticated and efficient automatic
tuning algorithms for control parameters
provide precise process control without
the presence of an operator.

Alarms

There are 8 alarm assignable to each sin­gle channel or to all (AND / OR logic) and
configurable as absolute, relative, direct,
reverse, window, latching or not, inhibit at
power-on.

Diagnostics

Geflex assures efficient process monito­ring from a thermal and electrical point
of view, allowing the operator to foresee
breakdowns or malfunctions and take
timely action (for example, in case the
temperature safety limit is exceeded, bro­ken probe, load fault).
The LBA alarm precisely checks the con­trol loop.

Current read (RMS)

• HB alarm load interrupted or partially
interrupted

• Calibration of HB alarm threshold via
automatic procedure starting from load
current level.
Alarm threshold is determined from
settable %
(ex.: if measured current =10A and
%=20, HB alarm threshold = 8A)
The procedure includes:

- start of requested power to maximum

- sampling of load current

- return to previous requested power
level for 3-phase load, three separate
alarm thresholds

• SCR in short circuit alarm

• Load in short circuit or overcurrent
alarm

• Unbalanced 3-phase load

Voltage read (RMS)

• Incorrect phase rotation diagnosis in
3-phase configuration.

• Phase loss alarm in 3-phase load
configuration

• Over temperature alarm

Output alarms configurable via software.

Heating control

For each zone, the heating control is
internally linked to the power output, no
other connections are necessary.

Cooling control (option)

For each zone, one of four types of coo­ling output is available:- relay, logic, triac
or continuous.

PROGRAMMING

The module is configured by setting sim­ple parameters.
No knowledge of programming language
is required.
The module can be configured in various
ways:

• using GFX-OP

• using GF_eXpress tool software

• using Industrial PC or PLC.

The software can be used to define the
state of alarm outputs or a preset power
level to be supplied in case of broken
probe. This assures continuity of service
in the individual zone.

Tuning

• Self-tuning: calculation of PID parameters
at system start.

• Auto-tuning continuous:continuous
adjustment of PID

• Autotuning one-shot: output modulation
and event-driven automatic PID parame­ ters re-calculation

Special functions

• Software Off: disabling of the control,
outputs are turned off.

• Inputs\outputs: direct management of
inputs/outputs, independently from
internal firmware.

• Simulation of four independent Geflex
units.

• Smart power management.

• Option:

- Soft start at timed power-on with or
without control of maximum current
reactivation after a settable shut-off
time.

- Current limit

- DT: Delay Triggering 0-90° on first
cycle (for inductive loads in modality
ZC or BF)

• Option for PA

- Soft start at timed power-on with or
without control of maximum current
reactivation after a settable shut-off
time.

- Soft stop at times power-off

• Feedback modes:

2

V or V

- Voltage feedback with maximum
voltage limit: controls by maintai­ ning constant voltage on the load
(proportional to P%_pid) regardless
of changes in line voltage

2

I or I

- Current feedback with maximum
current limit: controls by maintai­ ning constant current on the load
(proportional to P%_pid) regardless
of changes in line voltage or load
impedance

P

- Power feedback with maximum
power limit: controls by maintai­ ning constant power on the load
(proportional to P%_pid) regardless
of changes in line voltage or load
impedance.

You have to set the autocalibration para­meter each time you change feedback
mode.

DIGITAL COMMUNICATION

The product is furnished with standard
digital communication [PORT 1] used as
GFX4 connection to a HMI or Industrial
PC.
Also by a dedicated connector (10 pins)

it’s possible to connect the actual range

of Gefllex.
A second standard digital communication
(PORT 2) configurable by most popular
protocol:
CANopen, Euromap66, DeviceNet,
Profibus DP, Modbus RTU Modbus TCP,
Ethernet IP, EtherCAT, ProfiNET is avai­lable as option.

Net address

Assigned by two rotative selectors.

GENERAL DESCRIPTION

3

4

2

1

10

5

13

6

12

7

11

8

9

8

14

1. DIN rail frontal

2. power terminal: screws

3. power terminal

4. ventilation grid (do NOT obstruct)

5. hook/release device back DIN rail

6. hole for screws

7. configuration microswitches

8. standard digital communication

9. rotative selector switch

10. connectors J1, J2, J3, J4

11. fuses-holder (only for 30KW and 60KW models)

12. fuses-holder terminal (F1, F2, F3, F4/N)

13. power terminal (U1, U2, U3, U4)

14. ventilation grid (do NOT obstruct)