Simatek GFC 32 User Manual

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Manual

Control Unit

1400004_EN/05.2017

GFC 32

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Control Unit

SI MATE K A/ S

www.simatek.com Hotline: +45 4046 7525 [email protected]

Date: 05.2017

GFC 32

Index

Main features 3

2. Technical features 3

3. Installation guidelines 4

4. Preliminary checks 5

5. Electrical connections 5

6. Settings 6

7. Remote control 8

8. Shut down cleaning 8

9. Low pressure 8

10. Short circuit alarm of the outputs 9

11. Microprocessor failure alarm 9

12. Troubleshooting 10

13. Fuse table 10

14. Factory settings/Program menu 11

15. Legend 12

16. Simatek GFC 32:20: General assembly 13

17. Electric diagram for Simatek GFC 32: 20 valves 14

18. Declaration of Conformity 15

NOTE: Figures shown inside square brackets […] refer to positions on page 13. ATTENTION: Before use, read the instructions thoroughly to acquire sufficient knowledge of the product. For your

convenience, keep this sheet as a quick reference. Subject to change without notice.

Note: The GFC 32 unit is to be installed by trained personnel only!

Doc. No.: 1400004_

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Control Unit

SI MATE K A/ S

www.simatek.com Hotline: +45 4046 7525 [email protected]

_DK

Date: 05.2017

Enclosure

Grey ABS – transparent cover

Grade of protection

IP65

Dimensions

Simatek GFC 32: 20/32 outputs: case 296 x 256 x 118.

Weight

Simatek GFC 32: 20/32 outputs: approx. 3.5 kg.

Connections

Push in terminal plugs – max. section 2.5 mm².

Temperature

Storage: -20° C/+80° C. Operating: -10° C/+50° C, with duty cycle 30 %

Voltage available

Input: 230 V (±10%) – 50 /60 H z / Out p u t: 115/230/24V AC, 24 V DC.

Special version 24V DC/24V DC

Power consumption

Without output 2.5 VA. Output: max 25 VA / AC or 20 W / DC.

Pulse time

0.01 – 9.99 sec

Pause time

1 ÷ 999 sec

Max duty cycle

30 %

Remote control

Activated via external contact (normally open) fr e e of power.

Shut down cleaning

To be operated from the normally closed contact of fan remote contro l s w itc h

Alarm relay

Short circuit or Watch Dog (electronic surv e illanc e of the micr op ro c ess or ) Relay max 2 A – 250 V AC, free contact

Main fuse

1 A delayed 115-23 0 V; 2 A delayed 24-48 V AC and 24 V DC power supply

GFC 32

1. Main features

The Simatek GFC 32 has been designed to guarantee the control of diaphragm valves mounted on pulse jet dust collector filters containing filter bags or cartridges. The main features of the Simatek GFC 32 are:

⋅ Manual selection of Pulse and Pause time. ⋅ Can be operated by a remote pressure switch or PLC. ⋅ Automatic load search for connected valves, w hile ignoring outlets which have not been connected. ⋅ Shut down cleaning with selectable number of cycle s .

2. Technical features

Input: 115 V (±10%) – 50 /60 H z / Out p u t: 115/24V AC, 24 V DC. See page 6, 6.1

The device should be disposed of in accordance with current European regulations

The neutral of the power supply shall be connected to earth.

If this is not the case an isolation transformer is to be

installed and the neutral of the output to be earthed.

Otherwise the filter control will be damage d .

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Control Unit

SI MATE K A/ S

www.simatek.com Hotline: +45 4046 7525 [email protected]

Date: 05.2017

GFC 32

3. Installation guidelines

• Do not expose the control unit to direct sunlight in or der to prevent overheating of the circuit board.

• Connect the control unit to a continually power ed line to allow S HUT-DOWN CLEANING when the fan stops.

• Protect the control unit from rain, water inf iltration and humidity. Incomplete closing of the cover may cause

infiltration which can seriously d amage the circui t b o ard.

• Do not have cables entering via the upper part of the control unit.

• Do not install any electronic devices on vibrating structures.

• Use only cable glands with protection grade IP65 and of proper size (according to the cable used).

• A disconnecting switch has to be installed on the power line befo re the co ntro l unit.

• Do not attempt to repair the control unit – contact Sim atek!

• All wiring has to be carried out by a qualified electri c ian to prevent any r isk of f ire and electrical shocks.

• Control unit wiring has to be performed in such a way that the differe nt typ e s of cables, (po wer, relay’s contact,

valve output, 4-20 mA output) are kep t sep arate and no t passing c lose by the PCB .

• Before opening the unit make sure that the control unit is switched off (switc h o n/off [1] on 0 and wires on clamps [4] disconnected, including conne c tion to alarm/signal relays.

• All electrical connections of the contr ol unit, including solenoid valves, have to use separate paths in respect to the other loads.

• Voltage selector’s jumpers have to be positio ne d only by skilled personnel and following the instructions.

• A wrong voltage selector’s jumpers positio ning may cause potential danger to the personnel safety.

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Date: 05.2017

GFC 32

4. Preliminary checks

1. Check that the S ima tek GFC 32 does not have power (s w itch o n/of f [1 ] on 0 and terminals [4 ] disco nne c te d ).

2. Check that the s upply vo ltag e ind ic ate d on the yellow label [22] as “IN”, corresponds to the available power supply (Voltage end Frequency).

3. Check that the s upply vo ltag e to valv es ind i c ated on the ye llow label [22 ] as “OU T” , corresp onds to the voltage / frequency as indicated on the coils.

5. Electrical connections

1. Unscrew a nd remov e the terminals c o ve r [20].

2. Check that Sima te k GFC 32 does not have power (on/off switch [1] on 0 and terminals [4] disconnected).

3. Extrac t the removable terminals [2].

4. Check that the s upply vo ltag e to valv es ind i c ated on the ye llow label [22 ] as “OU T” corr e sponds to the voltage/frequency as indicated on the coi ls .

5. Connect the valve s to the terminal blocks [2], between terminal C and the numbered outputs.

6. Earthing [3] of the valves is necessary when output voltage is ≥48 V.

7. NEVER conne c t the Common or val ve outp ut to earth [3].

8. The Commons are inte rconnected on the printed circuit board.

9. The outputs are “s tatic ” type , with “ ze ro cro s s ing” com ma nd, to prevent elec trical disturbances.

10. Check that the valve connections are correct and isolate d in regard to earthing, by measuring the isolation between Ground [3] and Common with outputs terminal.

11. Put the extractable terminals [2] back in place .

12. Replace the terminals cover [20] and replace the scr ews .

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Date: 05.2017

GFC 32

6. Settings

6.1 Voltage selecti on

CHECK:

1. That the Simatek GFC 32 does not have power (switc h o n/off [1] on 0 and terminals [4] disconnected).

2. That the supp ly volta g e indi c ated on the ye llow lab e l [22] as “IN” corresponds to the available supply voltage (Voltage and frequency).

3. That the supp ly volta g e to valve s indic ate d o n the yello w lab e l [22 ] as “OUT ” corr e spo nds to the voltage/frequency indicate d on the coils.

If these 3 conditions are met, go to paragraph 6.2. Otherwise, carefully follow the procedure below!

A. Supply voltage selection

1. Unscrew the 2 screws [2 1] (optional), and open the Simatek GFC 32 transparent cover.

2. Remove the 4 screws of the front panel. Lift the front panel (do not remove it as it is connecte d to the ba se of the enclosure!).

3. Check that the s upply vo ltag e, se le c ta b le by jumper [5], cor responds to the one available from the supply voltage (e.g. both are set to 230 V).

4. Should the two volta g e s be diffe rent, m ov e the jum per [5 ] in order to selec t the same supp ly volta g e .

5. Go to point 6.1.B.

B. Selection of power supply to the valves

1. Check that the s upply vo ltag e to the valve s se le c table by jumpers [6] and [6 A ] corresp o nds to the supp ly voltage indicated on the coils of the valves (e.g . both are set to 24 V).

2. Should the two volta g e s be diffe rent, m ov e the jum pers [6] and [6A] in order to select the same supply voltage as indicated on the coils.

3. Caution: both jumpers [6] and [6A] must correspond to the same voltage!

4. Go to point 6.1.C.

C. Selection of power supply frequency to the valves (AC/DC)

1. Make sure that the output frequency to the valves, selectable by jumpers [8], corresponds to the value indicated on the coils (e.g. both are set to AC).

2. Should the two fr eque nc ie s are d iff er e nt, move the jump er s [8 ] in order to sele c t the same frequenc y as indicated on the coils.

3. Put the front p anel back in place a nd faste n the 4 screws.

4. Close the tr ansp are nt cover by means of the 2 screws [21] (optional).

Never select 115 or 230 V/DC for output!

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Date: 05.2017

1) Press SELECT MENU [9]:

The no. 1 will flash on the display [7]:

2) Press SELECT MENU [9]:

The no. 2 will flash on the display [7]:

3) Press SELECT MENU [9]:

The no. 3 will flash on the display [7]:

4) Press SELECT MENU [9]:

The no. 4 will flash on the display [7]:

5) Press SELECT MENU [9]:

The display [7] will show the letter E (run) and the number of the valve whic h is

next valve.

GFC 32

6.2 Parameters selection

Make sure that all electrical connections hav e been carr ie d out as described in paragraph 5. Switch on/off [1] on 1. LED WD [18] and LED Remote [16] are on. On the display [7] appears, for a few seconds, the

Simatek GFC 32 identification code. Once the code dis app e ars , the dis play will show the letter E (run) and the number of the valve which is going to be activated.

Using +/– buttons [10] select Pulse Time (0.01-9.99 sec ).

Using +/– buttons [10] select Pause Time (1-999 sec).

Using +/– buttons [10] select Pause Time in Shut down cleaning (1-999 sec).

Using +/– buttons [10] select the No. of cycles of Shut down cleaning (0-99). Select 0 if you don’t wish to have Shut down cleaning.

going to be activated - the cleaning c y c le starts. LED PULSE [11] will indicate that a valve is activate d .

LED PAUSE [12] will indicate that the Simatek GFC 32 is waiting to ac tiv a te the

NOTE!

⋅ Valves are pulsed from output No. 1 onwards. ⋅ The Simatek GFC 32 automatically skips any disconne c te d outputs , w hi le s howing the corresponding output

numbers on the display [7] in quick sequence. If no valves are connec ted, the dis play will show the numbers of all the outlets in sequence.

⋅ Check that during the first cleaning cycle every v alve is activated. ⋅ We suggest setting the Simatek GFC 32 working parameters to clean the fi lte r at the lowes t fr eque nc y po s s ible,

thereby reducing the little dust esc ape aris ing during jet-pulsing, achieving a longer lifetime of filter bags/cartridges and reducing the co mpre s s ed air cons umption.

⋅ Pause time should allow an efficient filter c le a ning in the worst co nditio ns , but should never be shorter than the

time needed to re-pressurise the compressed-air tank.

⋅ While selecting parameters (Select m e nu), S imatek GFC 32 will re tur n to nor mal operation if no buttons are

pressed within a 5 minute interval.

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Control Unit

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www.simatek.com Hotline: +45 4046 7525 [email protected]

Date: 05.2017

GFC 32

7. Remote control

Simatek fits the Simatek GFC 32 unit with a connection on terminals Re mote [26 ] and Common

NOTE

To activate Remote:

1. Unscrew a nd remov e the terminals c o ve r [20].

2. Remove the conne c tion from terminals Remote [26] and Common [37].

3. Bring an exter nal no-load and normally open (NO) contact to Remote [26] and Common [37] terminals from an external device (e.g. co ntac t fr om DP monitor).

4. Replace and s crew the terminals cover tight [20].

5. Close the contac ts on the Remo te [26 ] and Commo n [37 ] terminals in or der to enable the Remote function.

6. Should yo u open the contact on Remote [26 ] and Common [37] the Simatek GFC 32 will stop working and LED Remote [35] and LED Pause [12] will be off. Close the contact in order to start the cle aning cycle again from the position where it stopped.

8. Shut down cleaning

We suggest operating one or more cycles of Shut down cleaning at the end of each working session in order to remove the residual dust of the filter. Shut down cl e aning is s tarte d each time the fan is switc he d off.

In order to activate Shut down cleaning:

1. Select Paus e Time and number of cycle s of Shut dow n cleaning (see paragraph 6).

2. Unscrew a nd remov e the terminals c o ve r [20].

3. Bring an external no-load and normally closed (NC) contact to terminals Fan [36] and Common [37] from the fan switch.

4. Replace the terminals cover [20] and tighten the screws.

5. Shut down cle aning starts as soon as the Fan is switched off, contact on terminals Fan [36] and Common is closed, and LED Shut down [33] flashes.

⋅ NOTE: Should you have selected 0 at step 4 of paragraph 6.2, Simatek GFC 32 will stop working as soon as the

contact on terminals Fan [36] and Common [37] is clos e d (LED S hut down [33 ] is on).

6. Once Shut down cleaning is comple ted, L ED Shut down [33] will remain on. Switch the fan on in order to start cleaning cycle again. The cleaning cyc le sta r ts from the f irst valve.

9. Low pressure

You can connect a pressure gauge contact to terminals Low Pre ssure [29]. When the contact is closed the unit will stop working.

To activate Low Pressure:

1. Unscrew a nd remov e the terminals c o ve r [20].

2. Connec t an exter nal pr ess ure gauge contact to Low Pressure [29].

3. Replace the terminals cover [20] and fasten the screws.

4. Set the press ure gaug e at the minimum d esir ed press ure value, whe n the press ure is lower the contac t c lo ses and the unit will stop working.

[37]. If you wish to operate Simatek GFC 32 with a remote switch, read instructions below. If you do not wish to take advantage of this opportunity, do not remove the co nne c tio n.

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Date: 05.2017

GFC 32

10. Short circuit alarm of the outputs

The short circuit alarm is automatically activated by the Simatek GFC 32 (LED Alarm [17] is on) in order to signal failure of the solenoid/s. The Simatek GFC 32 will not ac tivate the o utputs in alarm, and will therefore exclude the faulty valves from the cleaning cycle.

In order to identify the faulty valves:

1. Press the key “+” [10]: The display [7] will show the letter A followed by the number of the output in alarm.

2. Keep press ing the ke y “+” [10] in order to identif y all of the outputs in alarm.

3. Press key “-” [10] to go back to E (run).

4. Perfor m the requir e d mainte nanc e .

5. Press Alarm reset [19]: The alarm is eliminated as the fault has been rectified. To have remote Alarm signal, connect to the relay’s terminals o n co ntac ts All com mon [38] and No [39 ] or Nc

[40].

11. Microprocessor failure alarm

LED WD [18] will switch off each time the microprocessor is faulty . T he c ustomer canno t solve the problem: contact Simatek. This will also activate the Alarm contact.

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Date: 05.2017

Problem

Probable cause

Solution

Display is blank and all LEDs are off.

No power supply.

Check the connections of the power selection of supply voltage.

Display shows all the numbers of the

No outputs connected.

Check connection to the valves [2].

Some valves are ignored by the Wrong electrical connections betwe e n

Check connections [2]. Coils are interrupted.

Check coils continuity.

Display shows the pulsing sequence

The secondary of the transformer is

Contact Simatek Power circuit is damaged.

Contact Simatek

Supply voltage to valves is different

Move jumpers [6] and [6A] in order indicated on the coils.

LED WD [18] is off.

Microprocessor failure.

Contact Simatek.

LED REMOTE [35] is off and Simatek

The bridge on terminals Remote [26]

Replace the bridge on terminals

Contact on terminals Remote [26]

Close the contact on terminals LED ALARM [17] is on.

Short circuit on one or more outputs.

See paragraph 10. Dimension

Value

Type

No. on drawing

Description

5 x 20

1A T [23]

Main fuse with 115/230 V supply

5 x 20

2A T [23]

Main fuse with 24/48 V supply

5 x 20

200 mA T [31]

External contacts supply

5 x 20

630 mA T [32]

Internal +5V supply (micro, display)

GFC 32

12. Troubleshooting

outlets in quick sequence.

Simatek GFC 32.

but valves are not functioning.

GFC 32 is in block.

IMPORTANT NOTE:

Should the Simatek GFC 32 unit be powered with 24 V DC, make sure inlet supply voltage is not lower than 24 V, and that voltage is proportioned to connected lo ads.

Simatek GFC 32 and coils.

interrupted.

from voltage indicated on the coils.

has been removed.

has been opened.

supply terminals [4] and the

to select the same power supply as

[26].

13. Fuse table

In case of replacement you must respect the values above.

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Recommended pause time s for SimPact®

GFC 32

14. Factory settings/Program menu

14.1 Pulse time

Simatek recommends a pulse time of 0.2 sec.

14.2 Pause time

By continuous cleaning, the pause time is calc ulated from a total cleaning time for the filter of 180 sec. See recommended pause time by continuous cleaning for the current filter type.

14.3 Pause time – Shut down cleaning

The pause time during shut down cleaning may be set as required according to the properties of the dust in que s tio n, however, the pause time must be correspond to the compressor capacity.

14.4 Shut down cycles

Bag cleaning will continue during the se t number of cyc le s (first valve to last valve) after connection betwe e n Fan [36] and Common [37], (fan stopped). Any equipment for removal of the separated dust should run during s hut down cleaning. Simatek recommends 2-3 cycles, as the current cycle is regarded as the first shut down cycle. Therefore the first cycle will not necessarily be a full cycle.

4T/4T-R filters

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GFC 32

15. Legend

[1] On/off switch [2] Push in valves terminals [3] Valve earthing [4] Power supply terminals [5] Jumper for inlet supply voltage selectio n [6] Jumper for voltage selection to valves [6A] Jumper for voltage selection to valves [7] Display [8] Jumper for frequency selection to valves [9] Push button Select Menu [10] Push buttons +/[11] LED Pulse [12] LED Pause [15] LED Low pressure [17] LED Alarm [18] LED WD (watch dog) [19] Push button Reset [20] Terminals cover [21] Transparent cover fixing screws (op tio na l) [22] Yellow label indicating IN/OUT voltage frequency [23] Fuse [24] Relay terminals [25] Product code and serial number [26] Terminals Remote [29] Terminal Low pressure [31] External contacts supply fuse [32] Internal +5V supply (micro, display) [33] LED Shut down [35] LED Remote [36] Terminals Fan [37] Common terminal [38] Alarm common terminal [39] Alarm No terminal [40] Alarm Nc terminal

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Date: 05.2017

GFC 32

16. Simatek GFC 32:20: General assembly

Doc. No.: 1400004

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Date: 05.2017

GFC 32

17. Electric diagram for Simatek GFC 32: 20 valves

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GFC 32

18. Declaration of Conformity

Doc. No.: 1400004

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