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)

Trigger modes

The GFX4-IR provides the following power control modes:

- modulation via variation of phase angle: PA modality

- modulation via variation of number of conduction cycles with “zero crossing” trigger”: ZC, BF, HSC modality.

PA - Phase angle

This mode manages power on the load by modulating load phase angle q
ex: if power to be transferred to the load is 100%, q = 180°
ex: if power to be transferred to the load is 50%, q = 90°

Zero Crossing mode

This function eliminates EMC noise. This mode controls power on the load via a series of conduction ON and non conduction OFF
cycles.

ZC - constant cycle time (Tc ≥ 1 sec, settable from 1 to 200 sec) Cycle time is divided into a series of conduction and non

conduction cycles in proportion to the power value to be transferred to the load.

For example, if Tc = 10sec, if the power value is 20% there is conduction for 2 sec (100 conduction cycles @ 50Hz) and non con­duction for 8 sec (400 non conduction cycles @ 50Hz).

BF - variable cycle time (GTT)
This mode controls power on the load via a series of conduction ON and non conduction OFF cycles. The ratio of the number
of ON cycles to OFF cycles is proportional to the power value to be supplied to the load.
The CT repeat period is kept to a minimum for each power value (whereas in ZC mode the period is always fixed and not
optimized).

Example of operation in BF mode with power at 50%. A parameter defines the minimum number of conduction cycles

settable (from 1 to 10). In the example, this parameter = 2.

HSC - Half single cycle
This mode corresponds to Burst Firing that includes single conduction cycles and half non-conduction cycles.

Example of operation in HSC mode
with power at 33 and 66%.

Softstart or Ramp at power-on

This type of start can be enabled in either phase control or pulse train mode.
With phase control, the increment of firing angle q stops at the corresponding power value to be transferred to the load.
The control of maximum current spike can be enabled during the ramp phase (this is useful in case of short circuit on the load or
loads with other temperature coefficients to automatically adjust the start time of the load).
The ramp is automatically re-enabled if the GFX4-IR remains off for a (settable) time.

Start ramp for resistive loads.

DT - “Delay triggering” of first cycle (only for control modes ZC, BF)
Settable from 0° to 90°.
Useful for inductive loads (transformer primaries) to prevent current spike that could in certain cases trip the high-speed
fuses that protect the SCRs.

DIMENSIONS - INSTALLATION

101,54

42140

147

82

109,5

92,5 35 19,5

92,5 35 19,5

147

140

4

140

140

140

111,5

182

195

101,5

109,5

4132

132 4

TECHNICAL DATA

INPUTS

IN1...IN4 [process analog inputs]

Connector: J4
Function: default process variable (con­figurable)
Sampling time: 120msec the four inputs
Accuracy: 0,2% FS ±1 steps at 25°C.
(16000 points)
Thermal drift: 0,005% FS/°C
Type

• Thermocouples ITS90: J, K, R, S, T,
custom (IEC584-1, CEI EN 60584-1,
60584-2). Internal cold junction com­pensation with automatic compensa­tion.
Selectable temperature range: °C/°F

• Thermoresistance: Pt100 DIN 43760

Max. resistance 20Ω

Selectable temperature range: °C/°F

• Voltage: range 0/12...60mV, Ri > 1MΩ

0/0,2…1V, Ri > 1MΩ custom 60mV at

32 sections

• Current: range 0/4...20mA, Ri = 50Ω
custom 20mA at 32 sections

IN5...IN8 [auxiliary analogue inputs]

Connector: J3
Function: default analog inputs reading

Sampling time: 480msec per TC, voltage
Accuracy: 1% FS ±1 steps at 25°C.

Type

• Thermocouple ITS90: J, K, R, S, T,
custom (IEC584-1, CEI EN 60584-1,
60584-2).
Internal cold junction compensation with
automatic compensation.

• Voltage: range 0/12...60mV, Ri > 1MΩ
Measurement of line Voltage and Current

• RMS current measurement function
Load current read; minimum measurable
current: 2A (30kW model), 4A (60kW
model), 6A (80kW model)

• Accuracy of RMS current measurement
2% f.s. at room temperature of 25°C in
ZC and BF firing modes; 3% f.s. in PA
mode with phase angle >90°, 10% f.s.
with phase angle <90°

• RMS voltage measurement function
Line voltage read; (acquisition of volta­ge values is valid for voltage in range

90...530VAC)

• Accuracy of RMS voltage measurement
1% f.s. with neutral connected; 3% f.s.
without neutral.

• Current and voltage sampling time

0.25 ms

DI1, DI2 [digital inputs]

Connector: J2
Function: default not enable (configurable)
Type
PNP, 24Vdc, 8mA (isol. 3500V)

OUTPUTS

OUT 1...4 [heating control]

outputs connected to solid state relay

Function: default heating control (confi­gurable)

OUT 5...8 [cooling control]

Connector: J1
Function: default cooling control (confi­gurable)

Type

• Relay: NO, max 3A, 250V/30Vdc, cosj
= 1 resistive load

• Logic: 24Vdc, 35mA

• Continuous - voltage: 0/2...10V, ±10V,

max 25mA short circuit protection

- current: 0/4...20mA, 500Ω max

- insulation: 1500V

• Triac: 230V/4Amp AC5
(0,8A for four) (1,6A for two)

OUT 9...10 [alarms]

Connector: J1a/J1
Function: default alarms (configurable)

Type

Relay: NO, max 5A, /30Vdc, cosj = 1

LEDs

RN ...........RUN state of the CPU

ER ...........error

DI1 ...........DI1digital input state

DI2 ...........DI2digital input state

O1 ...........Out.1 main input state

O2 ...........Out.2 main input state

O3 ...........Out.3 main input state

O4 ...........Out.4 main input state

COMMUNICATION PORTS

PORT 1 [local bus]

Connectors: S1/S2/S3
Function: local bus
Protocol:
Modbus RTU
Baud Rate: 115Kbps (default) setting

1200...115Kbps
Node address: setting by double rotati­ve selector
Connectors S1/S2: 2xRJ10 pins for flat
cable 4-4, RS485 2 wires insul. 1500V
Connectors S3: 10 pins for flat cable

PORT 2 [fieldbus]

Connectors: S4 / S5
Function: external fieldbus
Protocol:
Modbus RTU _________ 115Kbps
CANopen/Euromap 66 _ 10K...1Mbps
Profibus DP __________ 9,6...12Mbps
DeviceNet ___________
125K..500Kbps
Ethernet IP/Modbus TCP 10/100Mbps
EtherCAT ___________ 100Mbps
ProfiNET ____________ 100Mbps

See accessories

MICROSWITCHES

8 dip switches are available to select
wiring mode and different functionali­ties.

POWER

Load type

AC51

resistive or low-inductance loads

AC55b

short-wave infrared lamp (SWIR)

AC56a

ransformers, resistive loads with high

temperature coefficient

Switch-on modes

ZC

Zero crossing constant cycle time

(1-200sec)

BF

Burst Firing variable cycle time (GTT)

minimum or optimized

HSC

Half Single Cycle corresponds to Burst

Firing that manages Semi-cycles of on

and off. Useful to reduce flickering with

short-wave infrared loads

PA

Phase Angle

SSR [integrated power element]

Rated voltage: 480Vac

Work voltage range: 90...530Vac

Non-repetitive voltage: 1200Vp

Rated frequency: 50/60Hz self-adju-

sting

Rated current AC51 for zone

GFX4 30KW: 16A
GFX4 60KW: 32A
GFX4 80KW: 40A
(single channel 57A)

Rated current AC55b for zone

GFX4 30KW: 8A
GFX4 60KW: 16A
GFX4 80KW: 20A
for applications in which you can set a
minimum power output limit (ex: Lo.P
= 10%) by also limiting the lamp power
variation speed with gradient limit (ex:
G.out = 20%, PS.TM = 20s).
Under these conditions, the nominal
currents shown on the table can be
raised up to the values indicated for
AC51 type loads.

Rated current AC56b for zone

GFX4 30KW: 12A
GFX4 60KW: 25A
GFX4 80KW: 32A Trigger mode: ZC,
BF with DT (Delay Triggering), PA
with softstart

Non-repetitive overcurrent [t=20msec]

GFX4 30KW: 400A
GFX4 60KW: 600A
GFX4 80KW: 1150A

2

t per fusione [t=1...10msec]

I

GFX4 30KW: 645A
GFX4 60KW: 1010A
GFX4 80KW: 6600A

2

s

2

s

2

s
Dv/dt critical with deactivated output:
10,000V/ms High static dv/dt

Rated insulation voltage In/Out: 4000V

GENERAL FEATURES

Power supply: 24Vdc ±25%, max 8VA
Protection class: IP20
Working temperature range: 0...50°C
(see dissipation curves)
Storage temperature range: -20...+70°C
Relative humidity: 20...85% UR non­condensing
Installation: DIN EN50022 rail or panel
by screw

Dimensions: see dimensions and instal­lation

Weight:
models 30/60/80: 1200g.

models 30/60 with fusesolder:1600g.

ELECTRICAL CONNECTIONS

Triac Logic/continuous Relay

Load 1

Load 2

Load 3

Load 4

POWER SUPPLY

+24Vdc

c (OUT 5...8)

OUT 5

OUT 6

OUT 7

OUT 8

OUT 9

OUT 10

18...32Vdc

IN 5

IN 6

IN 7

IN 8

IN 1

IN 2

IN 3

1

no

no

no

no

c

no

c

no

6

J1a

9

Green

Red

Yellow

Yellow

Yellow

J1

9

1

J2

7

1

4

+VI

3

Tx/Rx­Tx/Rx+

GNDI
+VI

Tx/Rx­Tx/Rx+

GNDI

S1

S2

Port 1

2

1
4

3
2

1

S3

Yellow

Yellow

Yellow

J3

12

1

S4

Port 2

S5

J4

power

Model

max current

IN 4

Model without fuses-holder

30kW

16A

12

60kW

32A (30A)*

Model with fuses-holder

80kW

57A (40A)*

rigid

flexible

* UL certification

0,2 - 6mm

0,2 - 4mm

0,25 - 4mm

0,25 - 4mm

0,5 - 0,6Nm 0,5 - 0,6Nm 1,2 - 1,5Nm

2

2

24-10AWG

24-10AWG 0,2 - 4mm

2

23-10AWG 0,25 - 4mm

2

23-10AWG 0,25 - 4mm

0,2 - 6mm

2

2

24-10AWG 0,5 - 16mm

24-10AWG 0,5 - 10mm

2

23-10AWG 0,5 - 10mm

2

23-10AWG 0,5 - 10mm

2

2

2

2

20-6AWG

20-7AWG

20-7AWG

20-7AWG

ORDER CODE

Model

GFX4

30

(4x16A)

60

(4x32A)

(4x30A)*

80

(4x40A)

Current

(Amp)

max

for channel

range nominal working

Voltage (Vac) Power (kW)

16 24...530 480

32 (30)* 24...530 480

40* 57 24...530 480

110

230

400

480

110

230

400

480

110

230

400

480

total

contemporary

(4x16x110)

7

(4x16x230

14,7

(4x16x400)

25,6

(4x16x480)

30,7

(4x32x110)

14

(4x32x230)

29,4

(4x32x400)

51,2

(4x32x480)

61,4

(4x40x110)

17,6

(4x40x230)

36,8

(4x40x400)

64

(4x40x480)

76,8

single

channel

(16x110)

1,7

(16x230)

3,6

(16x400)

6,4

(16x480)

7,6

(32x110)

3,5

(32x230)

7,3

(32x400)

12,8

(32x480)

15,3

(40x110)

4,4

(40x230)

9,2

(40x400)

16

(40x480)

19,2

max for

single channel

(1x16x110)

1,7

(1x16x230)

3,6

(16x400)

6,4

(1x16x480)

7,6

(32x110)

3,5

(1x32x230)

7,3

(1x32x400)

12,8

(1x32x480)

15,3

(1x57x110)

62,7

(1x57x230)

13,1

(1x57x400)

22,8

(1x57x480)

27,3

* Certification UL

NOMINAL POWER

30KW 30

60KW 60

80KW 80

AUXILIARY OUTPUTS

Absents O

Relay R

Logic D

Continuous C

Triac T

GFX4-IR

FIELDBUS

O Absent

M Modbus RTU

P Probus DP

C CANopen

C1 Euromap 66

D Device Net

E Ethernet Modbus TCP

E1 Ethernet IP

E2 EtherCAT

E4 ProNET

E5 Real Time Ethernet

FUSES

O Absent

F Fuses-holder + fuses extrarapid (*)

2 Absent

(*) Available only for 30, 60kW power

4 4 Linear inputs (**)

(**) Option NOT available with Fieldbus E1 or E2 or E4 or E5

GEFRAN spa reserves the right to make aesthetic or functional changes at any time and without notice.

AUXILIARY INPUTS