Gefran GFX-M2, GFX-S2, GFX-E2 Data Sheet

GEFLEX Multifunction GFX-M2 / GFX-S2 / GFX-E2

MODULAR POWER CONTROLLER FOR TEMPERATURE CONTROLLED ZONES

Main applications

• Hot-runners

• Plastic extruders

• Plastic injection presses

• Blowers

• Plastic and rubber processing

machines

• Wrapping machines

• Packaging machines

• Thermal processes with

electric heating

Main features

• Three versions:
MASTER - independent temperature
control and communication unit
SLAVE - independent temperature
control unit
EXPANSION - for three-phase loads

• Protection: IP20

• Universal temperature input,
accuracy 0.2%

• Configurable digital input

• Logic output or "cooling" relay

• Load current detection with integrated
Current and Voltage Transformer

• Heat/cool PID, selection of cooling fluid,
self-tuning, auto-tuning “one-shot”,
soft-start

• 4 generic alarms, LBA and HB alarms

• 2 configurable relay outputs

• Field bus for Master
Standard: “Modbus RTU” with Serial 485
optically
Option: “PROFIBUS DP”, “CANopen” ,

“DeviceNet”

PROFILE

Extremely flexible and compact rear
panel instrument. Consists of a
“base” containing the PID micropro­cessor controller which holds a func­tional module such as: 5/10/15Amp
power solid state relay, double conti­nuous output, double relay, single
relay. Utilized mainly for heating hot
extrusion channels, injection, and in
all multizone configurations. In addi­tion, thanks to the use of popular field
buses, Geflex_Multifunction can be
integrated in various architectures.

Models and communication

The system has high communication
capacity and interfaces without limita­tion with the automation environment.
Three standard protocols are availa­ble: Modbus RTU, Profibus DP and
CANopen implemented in the Geflex
"master," which in turn communicates
with up to nine Geflex "slaves" by
means of an internal bus.
Every Geflex can tune to the network
communication speed (baud) with a
self-learning sequence.
In addition to connecting to PLCs,

terminals, and PCs, the "master" is
able to control a control loop

Modules

All of the following modules are com­pletely interchangeable.
Power:
Modules for three current levels: 5,
10, 15 Amp at 230/440V, single
phase. Each zone is completely inde­pendent from the adjacent one.
In addition, 3-phas loads can be con­trolled by adopting a Master/Slave
unit to which two Expansion units are
connected.
Double Continuous Output:
Module with two continuous outputs
configurable in current or voltage
(0/4...20mA, 0...10V) by means of
selectors on the module.
Double relay:
Module with two NO relay outputs
(3A, 250V).
The two control outputs are totally
configurable.
Single relay:
Single NO relay (12A, 250V).
The control output is totally configura­ble.

Mechanics

The mechanical elements have been
carefully designed and tested for
maximum ease of installation and to
guarantee high resistance to vibration
and thermal stress.

Diagnostic LEDs

The lower section has three LEDs
that indicate the functional state of
the main output, ERROR LED, and
RUN OK LED.
The upper section has a lamp which
signal the presence of voltage (on
power modules).

Temperature input

The temperature input is universal
and can be connected to a wide
variety of signal types: thermocou­ples, resistance thermometers, input
from 0...60mV, 0...20mA, 0...1Vdc,
transmitters, definable only by
software, without the need for exter­nal adapter shunts.
Accuracy of 0.2% guarantees excel­lent control of the heat process.

Integrated fuse

The base also contains the fuse pro-

tecting the SSR: the user does not
have to do any additional wiring.

PID

The control algorithm adapts to every
type of heat process.
Up to 14 different control modes are
available: from simple ON/OFF con­trol to single or double action
heat/cool PID; for cooling, simply
indicate the fluid being used.
Sophisticated and efficient algorithms
for automatic tuning of control para­meters provide precise process con­trol without user intervention.

Outputs and digital input

The instrument can have up to 3 out­puts: a cooling relay (3A, 250V), logic
(24Vdc, 35mA) or continuous
(0/4...20mA, 0...10V) and two optio­nal alarm relay outputs (3A, 250V).
The outputs are freely configurable
via software.
By means of internal bus, each
"slave" can activate the two relay out­puts on the "master" following alarm
conditions to create electrical clea­rance or block signals set to assure
safe operation of technological
systems.
This further reduces electromechani­cal wiring.
At the logic level, there are 4 generic
alarms configurable as: absolute,
deviation, direct, reverse, window, in
latching or non-latching mode, disa­bled at power-up.
With the isolated digital input always
available, you can select one of the
two pre-settable set points select
Manual-Automatic mode, reset the
alarms memory, or enable the hold
function.

Safety, diagnostics

At the logic level, there are 4 comple­tely configurable generic alarms.
Efficient diagnosis of the control loop
prevents breakdowns and lets the
user take timely action (for example,
in case of broken probe or load failu­re).
The LBA alarm carefully controls the
control loop, while the current tran­sformer (option) lets you directly
monitor the load and activate the HB
alarm in case of current failure or
SSR in short.
In addition, the voltage transformer
lets the user monitor line voltage,

power, and energy, with important
benefits for safety and plant effi­ciency.
Software can be used to define the
state of the alarm outputs or a preset
power level to be supplied in case of
a broken probe, thereby assuring
continuous service of the individual
module.
LEDs signal any fault in real time,
and powerful diagnostics is available
via serial.
A simple command from the digital
input deactivates the control zone by
"software shutdown" of the instru­ment.

Programming

The Geflex modules can be program­med via a supervisor (industrial PC,
HMI) or via the GFX_OP terminal
(see accessories). Both solutions pro­vide complete configurability and dia­gnostics for every Geflex
(Master/Slave).
For even simpler configuration, a pro­gramming kit (from notebook PC or
palm PC) is available, composed of
an IRDA interface unit and WIN­STRUM (a guided program for Win­dows environment - see technical
sheet).

TECHNICAL DATA

INPUTS

Input range: 0...60mV.
Sampling time: 120msec.
Accuracy: 0,2%fs ±1 scale points at
25°C.
Resolution : < 2µV for range 60mV.
Input filter: 0...20,0sec.
Zero offset adjustable in range:

-999...+999 scale points.

Main input

Thermocouple, Resistance Thermo­meter, Linear.
Application: process variable.
Thermocouples:
ITS90: J, K, R, S, T, custom.
Cold junction compensation: internal,
with automatic compensation.
Resistance Thermometer:
Pt100 DIN 43710, J Pt100, custom.
Linears/T

ransmitters:
range 0...60mV, 0...20mA, 0...1Vdc
(configurable within limits).
Possible 32 segment custom lineari­zation.

Load control with option

TA, TV internal:

Ammeter :

range 0...5/10/15Aac
Applications: control of current absor­bed by load.

Line tension:
range 0...480Vac.
Applications: control line tension,
power.

Digital input

PNP 24V, 8mA (isol. 3500V)
Applications: Man/Auto, Loc/Rem,
Hold, Reset alarms, Select setpoint,
shut down software.

Auxiliary input (option)

Potentiometers ≥ 1KΩ
0/2...10V (Ri > 100KΩ)
0/4...20mA (Ri > 500Ω).

OUTPUTS

Max 3 Relays / 1 Logic + 2 Relays.

- Relay

(Up to 3), NO, max 3A, 250V resisti­ve load.
Application: cooling, alarms.

- Logic

24Vdc, 35mA.
Application: cooling, alarms.

- Continuous

0...10V; 0/4...20mA
Application: cooling, alarms.

DIGITAL COMMUNICATION,
FIELD BUS

Asynchronous serial transmission.
Standard protocol: MODBUS RTU
RS485 2 wires, 1200...19200 baud.
Optional protocol: CAN OPEN
10K...1M bit/sec, PROFIBUS DP
9,6...12Mbit/sec.

Safety

Detection of short circuit or opening
of input probe, open loop alarm
(LBA), load fault alarm (HB),
overheat SCR.

PROCESS CONTROL FUNCTIONS

Control

PID, PI, PD, P, On/Off, heat, cool,
heat + cool with fluid selection.
Manual/Automatic: Bumpless or with
manual forcing of output.

Tuning

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

- Auto-tuning: continuous adjustment
of PID.

Special functions

Soft-start, power limitation, software
shut down.

Alarms

Up to 4:
absolute, deviation, symmetric, direct,

reverse, latching and non, LBA, HB.
Reference : PV, SP, auxiliary input
(for HB).

Multiset

Double setpoint with gradient selecta­ble from digital input

POWER SUPPLY

24Vdc ±25%, 5W

POWER MODULE

5A 10A 15A

NOMINAL VOLTAGE 230Vac 440Vac 230Vac 440Vac 230Vac 440Vac
RATED WORKING VOLTAGE 24...253Vac 24...484Vac 24...253Vac 24...484Vac 24...253Vac 24...484Vac
NON-REPETITIVE VOLTAGE 500Vp/800Vp 500Vp/800Vp 500Vp/800Vp
SWITCHING VOLTAGE FOR ZERO ≤ 20V
RATED FREQUENCY 50...60Hz
CORRENTE NOMINALE AC1 5A 10A 15A
NON-REPETITIVE OVERCURRENT (t=20ms) 80A 120A 160A
dv/dt CRITICAL WITH OUTPUT DEACTIVATED 500V/µs
RATEDISOLATION VOLTAGE IN/OUT 2500V
WORKING TEMPERATURE (see dissipation curves)
CONNECTION FASTON4,8 x 0,5 mm
Weight 50gr 50gr 120gr
Protection IP20