Gefran IR-12, IR-24 Data Sheet

Main Applications

• Welding of composites and
plastics

• Preheating on Blow Molding
lines

• Thermoforming

• Multichannel applications with
infrared lamps

IR-12 / IR-24

MULTICHANNEL POWER CONTROLLER

Main Characteristics

• 12 and 24 independent 9A channels

• Fast Zero-Crossing, Half-Single-Cycle
and Phase-Angle control

• Built-in extra-rapid fuses

• Current balancing with time-sharing

• Voltage swing compensation

• Voltage and current diagnostics
(interrupted load, line voltage)

• Diagnostics of SCR temperature, SCR
short circuit, open fuse

• Modbus and Profinet communication

PROFILE

Powerful and compact IR12 and IR24

Multichannel Power Controllers are the ideal
solution for heating systems that use any
type of infrared lamps.
With an “all-in-one” philosophy, all of the
elements needed for complete control of IR
lamp groups (for total power up to 60 kW)
are contained in a robust, compact metal
container that mounts on the wall.
There are various models: IR-24 with
24 independent control output and IR-12
with 12 outputs, both with Modbus RTU or
Profinet Fieldbus communication options.

C

ommand

The 12 or 24 channels are commanded via
Modbus RTU serial communication (max
57,600bps) or via Profinet.
Each channel is commanded independently.

P

ower

Each control output can deliver a maximum
current of 9A, including simultaneously on
all channels, up to 216 Amps for IR24
models.

C

ontrol

The Soft-start function, provided in Phase
Angle mode, guarantees gradual initial hea­ting of lamps, reduces current spikes, and
lengthens life cycle.

After the Soft-start phase, when the filament
is hot, the lamp can be controlled in “Burst
Firing” or “Half Single Cycle” mode.
Complete Phase Angle control can always
be chosen. In detail, the control modes,
configurable via SW, are:
BF: Burst Firing
Zero crossing with optimized cycle time:
ideal for fast heating systems with medium­wave IR lamps.
HSC: Half Single Cycle
Zero crossing similar to BF, but able to con­trol half-waves, making it perfect for short
wave lamps as well because it greatly limits
flickering without generating EMC noise;
therefore, expensive and bulky EMC filters
are not needed.
PA: Phase angle
Modulating the conduction angle of each
wave allows more precise and stable control
of IR lamps.

T

ime sharing

Continuous monitoring of power percen­tages on outputs allows intelligent “time­sharing” distribution of outputs and provides
continuous balancing of total instantaneous
current levels on each of the three phases.

This reduces spikes, increases the system’s

power factor, and saves energy.

L

ine voltage compensation

Automatic compensation ensures correct
power to loads even in the presence of
voltage swings.

D

iagnostics

Great attention is given to general and spe­cific diagnostic functions for every output,
with signal LEDs and specific diagnostic bits
readable from serial and Fieldbus.

- Current Diagnostics:
Total load interrupt alarm
SCR short circuit alarm

- Voltage Diagnostics:

Alarm for absence of phase

- Fuse Diagnostics

Fuse break signal (for each output)

- Temperature Diagnostics
Alarm for over–temperature of power
module

The IR-24 and IR-12 Controllers are comple-

tely configurable via GF_ eXpress, Gefran’s

powerful SW configuration tool for all of its
devices.

TECHNICAL DATA

Power supply

Overvoltage
category

Rated current

Rated power

Control mode

Circuit breakers 24 AC-switch monophase with pair of 1200V SCRs in antiparallel

Functions

Serial
communication

Protections and
Alarms

Signal LEDs

I/O logic signals

Electrical
connections

Cooling

Working
temperature

Relative humidity 10....95% without condensation

CPU Supply 230 Vac ± 10 % 50/60 Hz 20 VA
Power circuits 480Vac (VF/N= 270Vac) ±10% 50-60Hz

2 (industrial devices with permanent connection to power grid)

Model IR-24 9A x 8 zone = 72A per ogni linea trifase (72A x 3)
Model IR-12 9A x 4 zone= 36A per ogni linea trifase (36A x 3)
Model IR-24 49.6 kW @ 230Vac (72A x 230Vac x 3)
Model IR-12 24.8 kW @ 230Vac (36A x 230Vac x 3)

PA Modulation with phase-angle control

BF

HSC Zero-Crossing modulation at half-wave with optimized cycle time (ex.: short-wave IR lamps)

Power control

Measurement Effective value of three effective line voltages RN , SN and TN
Diagnostic State of any alarms on each channel and overall state of module

MODBUS (option M)

PROFINET (option E4)

Circuit break in presence of
control

Current crossing in absence
of control

Over temperature power
card 1

Over temperature power
card 2

PW Presence of voltage to CPU green
WD Watch Dog tripped, CPU function blocked yellow

L1 Presence of phase L1 (presence of crossing for zero) green
L2 Presence of phase L2 (presence of crossing for zero) green
L3 Presence of phase L3 (presence of crossing for zero) green

FAULT Presence of one or more alarm conditions, differentiated with ashing red

RX State of Rx serial line green
TX State of Tx serial line green

IN1...4 Inputs state green

OUT1...4 Outputs state LED green

24V Presence of voltage for 24V digitals green

OK Output OK: Correct operation of digital outputs green
4 Logic inputs 24V Optoisolated, current draw 20mA
4 Logic outputs 24V Optoisolated, maximum deliverable power 250mA

Auxiliaries power supply

Power supply

Earthing Power connector for ex cable from 0.5 to 16 mm² (AWG 10-2) 1

Power outputs

RS 485 D-Sub 9 pin female connector in parallel (Female) 2

Logic I/Os

Power board forced air with 2 24VDC 3.6W fans (only 1 fan for IR-12)
Control board natural convection

0....40°C

Zero-Crossing modulation at full-wave with optimized cycle time (ex.: medium-wave IR
lamps)

Control, linearization, ON percentage compensation for each of 24 channels based on
control received, internal tables, and actual line voltage (according to selected mode)

- Protocol: MODBUS RTU

- Address: 1 ... 99 selectable by 2 RotarySwitch

- N. 2 Connectors DB9 (X5, X6)

- Baud rate: congurable 1200 ... 57600 bit/s (default = 57600)

- Serial RS485 optoisolated

- Protocol: PROFINET-IO

- N. 2 Ethernet port RJ45: ETH0, ETH1

- Internal Switch

- Baudrate: 100 Mbit/s

- Auto-Crossover

- Address Switch integrated DCP

- Message supported: Cyclic / Acyclic

- N. 4 status Leds (Link / Signal, for each Ethernet port)
Interrupted load signal (for each output)

Signal for broken fuse /SCR that does not close (for each output)

Signal for SCR in short (for each output)

Insufcient cooling of power card 1 by heat-sinks, collective trip with block of phases invol­ved

Insufcient cooling of power card 2 by heat-sinks, collective trip with block of phases invol­ved

2-pole extractable terminal block, pitch 7.62mm, 400V/20A for ex cable
from 0.2 to 4 mm² (AWG 4-10), with screw ange (Male)

Single power connectors, 500V/101A for ex cable from 10 to 25 mm²

(AWG 20-4)

8-pole extractable terminal block, pitch 7.62mm, 400V/20A for ex cable
from 0.2 to 4 mm² (AWG 4-10) , with screw ange (Male)

10-pole extractable terminal block, pitch 5.08 mm, 250V/12A, with screw

ange (Male)

1

4

3

1

Type “Book” format: closed painted plate box, ready to install in panel, with ventilation slits

220-254Vac

50/60Hz

CONTROL LOGIC

CPU

LOGIC

IN1,IN2,IN3,IN4

OUT1, ...,OUT4

LOGIC

AC / DC

+/-5V

AC / DC

5V

Low voltage

+5Vdc, 3,3Vdc

CONTROL LOGIC / CPU

High Voltage 400-480Vac

Three-phase + Neutral

Low Voltage 5Vdc

Serial PORT

SCR OUTPUT

AC / DC

5Vdc

OUT

L1.1 to L1.8

SCR

9 Arms

AC / DC

+24Vdc

Low voltage 24Vdc

FAN

L1,L2,L3

VOLTAGE

MEASURE

External I/O voltage

24Vdc

FAN1

FAN2

NTC over

temperature

FUSE

L1.1toL1.8

FUSE

L2.1toL2.8

FUSE

L3.1toL3.8

SSR, FUSE, LOAD

diagnostic

Serial PORT

MODBUS RS485

or

FIELDBUS

OUT

L2.1 to L2.8

SCR

9 Arms

OUT

L3.1 to L3.8

SCR

9 Arms

Dimensions (mm) Height without fastening ange 350

Container

Dimensions External (mm)

Weight

BLOCK DIAGRAM

Depth 280
Width 215
Support in panel 410 x 215
IR-24 14 Kg
IR-12 12 Kg