Gefran GFX4-IR Data Sheet

Main application
• Thermoforming
• Blowing
• Hot runners for injection presses
• Fiber weaving
• Heat treatment furnaces
• 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
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