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: congurable 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)
Insufcient cooling of power card 1 by heat-sinks, collective trip with block of phases involved
Insufcient 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
GENERAL DESCRIPTION
Front view with MODBUS communication
1. Diagnostics LED
2. Modbus address (Rotary switch)
3. I/O LEDs
4. I/O connector
5. Modbus serial connector
6. CPU power supply (230VAC) 400-480VAC line
7. Line power terminals 400-480VAC (3F + N, Ground)
8. Fuse holders with protection fuses (24 for IR24, 12 for IR12)
9. Output connectors (to load)
10. Cooling fan unit
GENERAL DESCRIPTION
Front view with PROFINET Fieldbus
1. Diagnostics Leds
2. Ethernet port ETH0, ETH1
3. I/O LEDs
4. Ethernet port ETH0, ETH1 status Leds indication
5. I/O connector
6. CPU power supply (230VAC)
7. Line power terminals 400-480VAC (3F + N, Earth)
8. Fuse holders with protection fuses (24 for IR24, 12 for IR12)
9. Output connectors (to load)
10. Cooling fan unit
WIRING DIAGRAM
Connection example: IR-24 connected to 24 loads
WIRING DIAGRAM
Connection example: IR-12 connected to 12 loads
ORDERING CODE
IR -
NUMBER OF ZONES
24 24
12 12
MODEL DESCRIPTION CODE
IR-12-M 12 Zones, Modbus RTU serial communication F062606
IR-12-E4 12 Zones, Fieldbus Pronet serial communication F062611
IR-24-M 24 Zones, Modbus RTU serial communication F062605
IR-24-E4 24 Zones, Fieldbus Pronet serial communication F062612
GEFRAN spa reserves the right to make esthetic or functional changes at any time and without notice.
COMMUNICATION
M MODBUS RS485
E4 PROFINET
UL
Conformity C/UL/US File E243386 Vol1 sec.6
The instrument conforms to the European Directives 2004/108/CE and 2006/95/CE with reference to the generic standards:
- EN 60947-4-3 (Product) - EN 61010-1 (safety)
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