gefran GFW 400A User manual

1
80999D_MHW_GFW 400-600A_07-2020_ENG
GFW 400-500-600A
MODULAR POWER CONTROLLER
INSTALLATION AND
OPERATION MANUAL
Software version: 01:00
code 80999C - 05-2019 - ENG
INDEX
GRAPHIC SYMBOLS
To differentiate the type and importance of the information in this User Manual, graphic reference symbols are used to make such information easier
to interpret.
Indicates contents of sections, general instructions, notes,
and other points to which the reader’s attention needs to be
called.
Indicates a suggestion based on the experience of GEFRAN’s
Technical Personnel that could be especially useful under
certain circumstances.
Indicates a particularly delicate situation that could affect
the safety or correct operation of the controller, or an
instruction that MUST be followed to prevent hazards.
Indicates a reference to Detailed Technical Documents
available on the GEFRAN website www.gefran.com.
Indicates a risk to the user’s safety due to high voltage at the
points indicated.
1 • PRELIMINARY INSTRUCTIONS....................................2
1.1 Prole........................................................................ 2
1.2 General Description .................................................. 2
1.3 Preliminary instructions............................................. 3
2 • INSTALLATION AND CONNECTION............................4
2.1 Electrical power supply ............................................. 4
2.2 Notes on electrical safety and electromagnetic
compatibility: ............................................................ 4
2.3 Recommendations for Correct Installation for purposes
of EMC...................................................................... 4
2.4 Dimensions ............................................................... 7
2.5 Template dimensions................................................ 8
2.6 Installation................................................................. 8
2.7 Short circuit protection .............................................. 9
2.8 General description GFW ........................................ 10
2.9 Cleaning/checking or replacing the fan.................... 11
2.10 Replacing the internal fuse (Optional) ..................... 12
2.11Cardinsertionforeldbusinterface ......................... 13
3 • ELECTRICAL CONNECTIONS ......................................14
3.1 Power connections .................................................. 14
3.2 Functions of leds indicators ..................................... 16
3.3 Description Input/Output .......................................... 17
3.4 Description of dip-switches ...................................... 23
3.5 Serial communication ports ..................................... 24
3.6 Connection example: Power section ....................... 30
3.7 Notes: use with inductive loads and transformers ... 38
3.8 Trigger modes.......................................................... 38
3.9 Digital input (PWM).................................................. 42
4 • INSTALLATION OF “MODBUS” SERIAL NETWORK43
4.1 “AUTOBAUD SERIAL 1” sequence ......................... 44
5 • TECHNICAL CHARACTERISTICS ................................45
5.1 Derating Curves....................................................... 49
6 • Commercial Information ................................................50
6.1 Order code............................................................... 50
6.2 Accessories ............................................................. 51
6.3 Fuses ....................................................................... 52

280999D_MHW_GFW 400-600A_07-2020_ENG
1.1 Profile
The “GFW” from 400A to 600A series of microprocessor advanced solid
state power units controls high electric powers with different types of
heating elements, single-phase, biphase or triphase.
Current levels range from 400A to 600A, nominal voltage from 480Vac
,600Vac, 690Vac.
The command input is congurable and accepts 0-10V, 0/4- 20mA
signals, potentiometer, logic signals, including with PWM modes for cost
effective solutions.
The device can also be operated via Modbus RTU serial communication,
with IN/OUT chain connections facilitated by plug-in RJ10 (telephone)
connectors.
The several trigger modes are software congurable and provide:
- ZC: Zero Crossing constant cycle time (settable in range 1-200sec),
for conventional loads
- BF: Burst-Firing, Zero crossing with optimized minimum cycle time,
for systems with low thermal inertia, medium-wave IR lamps
- HSC: Half Single Cycle Zero Crossing corresponds to Burst Firing that
manages single semi-cycles of conduction or stop cycles, useful
for short-wave IR lamps, reduces ickering and limits generation
of EMC noise on the power line (applied only to single-phase load
or open delta).
- PA: Phase angle control, useful for short-wave IR lamps, transformer
primaries. Completely eliminates ickering of load laments, but
generates EMC noise on power line (harmonics).
Soft Start ramp functions can be assigned to these controls, with options
such as “current limit” that keeps current peaks at power-on and RMS
current level at full power under control. Thanks to sophisticated Hardware
and Software solutions, you can precisely control different types of loads.
Phase angle control (the only control method that completely eliminates
IR lamp ickering), matched with current, voltage, or load power
feedback functions, let you condently use “critical” applications such as
(for example), special resistors such as special Super Khantal™ heating
elements, Silicon Carbide resistors, or transformer primaries either
single-phase or triphase.
GFW runs complete diagnostics of current, voltage, power, and
temperature levels:
Current Diagnostics:
- Total and partial load interrupt alarm
- Self-learn function of alarm limit for interrupted load
- Alarm for SCR in short circuit
- Alarm for load in short circuit or overcurrent
- Alarm for interrupted internal fuse
Voltage Diagnostics:
- Alarm for absence of phase
-Signal for incorrect rotation of 3 phases (for triphase applications)
- Alarm for triphase line unbalance
Temperature Diagnostics:
- Measurement of power module temperature
- Alarm for over temperature of power module
- Measurement of power terminals temperature
- Alarm for over temperature of power terminals
-Alarm for absence of 24V supply to cooling fan
Power control with Soft start ramp limits load, optimizes the consumptions
and increases the load operating duration.
Parameters can be congured from an optional keypad with LCD screen
that attaches magnetically to the front panel and from PC with the
GF_eXpress conguration kit, which lets you save all parameters in a
conguration le that is easy to manage and to copy to other devices.
GFW always provides an RS485 serial connection (PORT1) with Modbus
RTU protocol to control currents, voltages, powers, load status, and
device status from the supervisor terminal (HMI) or PLC.
A second (optional) communication port is offered that lets you choose
from among the following Fieldbuses: Modbus RTU, Probus DP,
CanOpen, Devicenet, Modbus-TCP, Ethernet IP, EtherCAT .
The section contains general information and warnings to be
readbeforeinstalling,conguringandusingthecontroller.
1.2 General DescriPtion
GFW is an extremely compact multi-zone advanced solid state power
unit equipped with different optional functions; it offers an exclusive
combination of performance, reliability, and exibility.
In particular, this new line of Gefran solid state relays is the ideal solution
for sectors demanding high performance and continuity of service, such
as:
• Thermoforming
• Blowing
• Hot runners for injection presses
• Texturizing of bers
• Heat treatment furnaces
• Woodworking machines
• Glass tempering furnaces
The modules Series GFW are based on an extremely versatile hardware
and software platform, with options to select the best I/O conguration
for your system.
GFW is used for the power control of single-phase, Dual-Phase and
3-phase loads, including resistive loads with high and low temperature
coefcient, short wave IR lamps, or transformer primaries.
Attention:thedescriptionofprogrammingandconguration
parameters are contained in the “Programming and
conguration” manual, downloadable from the website
www.gefran.com
1 • PRELIMINARY INSTRUCTIONS

3
80999D_MHW_GFW 400-600A_07-2020_ENG
1.3 Preliminary instructions
Please read the following preliminary warnings before
installing and using your GFW modular power controller.
This will help you begin using the controller rapidly and
prevent a number of problems that could erroneously be
interpreted as malfunctions or limitations of the controller.
Immediately after unpacking the unit, check the order code and the other
data on the label attached to the outside of the container.
Write them on the following table.
This data must always be available and given to Gefran Customer Care
representatives if technical service is needed.
SN................................ (Serial Number)
CODE .......................... (Product code)
TYPE............................ (Order code)
SUPPLY....................... (Type of electrical power supply)
VERS. .......................... (Firmware Version)
Check that the controller is in perfect condition, was not damaged during
shipment, and that the package also contains the CD that contains other
useful information such as the “Conguration and Programming” manual,
memory map etc...
Immediately report any errors, shortages, or signs of damage to your
Gefran dealer.
Check that the order code matches the conguration requested for the
intended application by consulting the section:
“Technical-Commercial Information.”
Example: GFW-1PH 400 - 690 - 0 - 0 - 1- ...
Model
Nominal current
Nominal voltage
Contol option
Current limit
Output sAux. 4
Relay
... etc. ...
See paragraph “ Dimensions and mounting” before installing the GFW on
the machine/host system control panel.
To congure the PC use the SW Gefran GF-Express kit and the relative
connection cable.
For the order code, see Section “Technical-Commercial Information”.
Users and/or system integrators who want detailed
information on serial communication between Gefran
standard and/or industrial PCs and Gefran Programmable
Instruments can access Technical Reference Documents on
serial communication and MODBus protocol, etc., in Adobe
Acrobat format on the Gefran website www.gefran.com:
• Serial Communication
• MODBus Protocol
• FIELDBUS protocols (Various)
Before calling Gefran Customer Care in case of assumed malfunctions,
please see the Troubleshooting Guide in the “Maintenance” section and,
if necessary, the F.A.Q. (Frequently Asked Questions) section on the
Gefran website www.gefran.com

480999D_MHW_GFW 400-600A_07-2020_ENG
2 • INSTALLATION AND CONNECTION
This section contains the instructions needed for correct
installation of GFW modular power controller on the machine/
host system control panel and for correct connection of the
power supply, inputs, outputs and interfaces.
CAREFULLY READ THE FOLLOWING WARNINGS
BEFORE INSTALLING THE INSTRUMENT!
Disregard of such warnings could create electrical
safety and electromagnetic compatibility problems, as
well as void the warranty.
2.1 electrical Power suPPly
• The controller DOES NOT have an On/Off switch: the user must install
switch/isolator conforming to safety requisites (CE mark) to cut off
the power supply up-line of the controller.
The switch must be installed in the immediate vicinity of the controller
in easy reach of the operator.
A single switch can be used for multiple devices.
• The earth connection must be made with a specic lead
• If the product is used in applications with risk of harm to
persons or damage to machines or materials, it MUST
be equipped with auxiliary alarm devices.
It is advisable to provide the ability to check for tripped alarms
during regular operation.
DO NOT install the product in rooms with hazardous (inammable
or explosive) atmosphere; it may be connected to elements that
operated in such atmosphere only by means of appropriate interfaces
that conform to current safety standards.
2.2 notes on electrical safety anD
electromaGnetic comPatibility:
2.2.1 CE MARKING: EMC
(electromagnetic compatibility) conformity
in compliance with Directive 2014/30/EU and following modications.
Series GFW are mainly intended for industrial use, installed on panels
or control panels of production process machines or systems.
For purposes of electromagnetic compatibility, the most restrictive
generic standards have been adopted, as shown on the table.
2.2.2 LV (low voltage) conformity
Under Directive 2014/35/EU.
EMC compliance has been veried with respect to the
information in Tables 1 and 2.
2.3 recommenDations for correct installation
for PurPoses of emc
2.3.1 2.3.1 Instrument power supply
• The power supply for the electronic instrumentation on the panels
must always come directly from a cut-off device with fuse for the
instrument part.
• Electronic instrumentation and electromechanical power devices such
as relays, contactors, solenoids, etc., MUST ALWAYS be powered by
separate lines.
• When the power supply line of electronic instruments is heavily
disturbed by switching of thyristor power groups or by motors, you
should use an isolation transformer only for the controllers, grounding
its sheathing.
• It is important for the system to be well-grounded:
- Voltage between neutral and ground must not be > 1V
- Ohmic resistance must be < 6Ω;
• If the grid voltage is highly unstable, use a voltage stabilizer.
• In proximity of high-frequency generators or arc welders, use adequate
grid lters.
• The power supply lines must be separate from instrument input and
output lines.
• Supply from Class II or from limited energy source
2.3.2 Input and output connections
Before connecting or disconnecting any connection, always check that
the power and control cables are isolated from voltage.
Appropriate devices must be provided: fuses or automatic switches to
protect power lines.
The fuses present in the module function solely as a protection for the
GFW semiconductors.
• Connected circuits must be ully isolated from external electrical noise.
• To connect analog inputs, strain gauges, linears, (TC, RTD), you have
to:
- physically separate the input cables from those of the power supply,
outputs, and power connections.
- for inputs use braided and shielded cables, with sheathing grounded
at a single point.
2.3.3 Installation notes
Use the extra-rapid fuse indicated in the catalogue according to the
connection example equipped.
- Moreover, the applications with solid-state units require a safety
automatic switch to section the load power line.
To ensure the high reliability of the device, it is necessary to install it
properly inside the panel so to obtain an adequate thermal exchange. Fit
the device vertically (maximum angle 10° to the vertical axis) see gure 3
• Vertical distance between a device and the panel wall >100mm
• Horizontal distance between a device and the panel wall at last 10mm
• Vertical distance between a device and the next one at last 300mm.
• Horizontal distance between a device and the next one at last 10mm.
Check that the cable holder runners do not reduce these distances, in
this case t the cantilever units opposite the panel so that the air can ow

5
80999D_MHW_GFW 400-600A_07-2020_ENG
vertically without any obstacles.
• dissipation of device thermal power with effects on installation room
temperature.
• thermal power dissipation with limits on installation room temperature.
• requires exchange with external air or an air conditioner to transfer
dissipated power outside the panel.
• maximum limits of voltage and derived power of transients on the line,
for which the solid state power unit contains protective devices (based
on the model).
• presence of dispersion current in GFW in non-conducting state (current
of a few mA due to RC Snubber circuit to protect the thyristor).
GEFRAN S.p.A. assumes no liability for any damage
to persons or property deriving from tampering,
from incorrect or improper use, or from any use not
conforming to the characteristics of the controller and
to the instructions in this User Manual.
Table 1 EMC Emission
AC semiconductor motor controllers and conductors for non-motor
loads
EN 60947-4-3
Emission enclosure
compliant in ring mode single cycle and phase angle if external
lter tted
EN 60947-4-3
CISPR-11
EN 55011
Class A Group 2
Table 2 EMC Immunity
Generic standards, immunity standard for industrial environments EN 60947-4-3
ESD immunity EN 61000-4-2 4 kV contact discharge
8 kV air discharge
RF interference immunity EN 61000-4-3 /A1 10 V/m amplitude modulated
80 MHz-1 GHz
10 V/m amplitude modulated
1.4 GHz-2 GHz
Conducted disturbance immunity EN 61000-4-6 10 V/m amplitude modulated
0.15 MHz-80 MHz
Burst immunity EN 61000-4-4 2 kV power line
1 kV I/O signal line
Surge immunity EN 61000-4-4/5 Power line-line 1 kV
Power line-earth 2 kV
Signal line-earth 2 kV
Signal line-line 1 kV
Magnetic elds immunity Test are not required.
Immunity is demonstrated by
the successful completion of
the operating capability test
Voltage dips, short interruptions and voltage immunity tests EN 61000-4-11 100%U, 70%U, 40%U,
Table 3 LVD safety
Safety requirements for electrical equipment for measurement,
control and laboratory use
EN 61010-1
UL 508
ATTENTION
This product has been designed for class A equipment. Use of the product in domestic environments may cause radio interference,
in which case the user may be required to employ additional mitigation methods.
EMC lters are required in PA mode (Phase Angle, i.e., SCR trigger with phase angle modulation).
The lter model and current level depend on the conguration and load used.
The power lter MUST by connected as close as possible to the GFW.
You can use a lter connected between the power line and GFW or an LC group connected between the GFW output and the load

680999D_MHW_GFW 400-600A_07-2020_ENG
GFW-400/600A INSULATION DIAGRAM
INPUTS
POWER SUPPLY
CPU
PORT 1
PORT 2
TA INPUT (I_load)
TA1, TA2, TA3
4KV
Main Processor
EEprom
RAM
LEDs
OUTPUTS
OUT9, 10
Fieldbus MODBUS RS485 Ethernet Modbus TCP Ethernet-IP Ethercat CanOpen Probus
Supply 18 …32V
MODBus RS485
ANALOG COMMAND INPUT
DIGITAL INPUTI DI1, DI2, DI3, DI4
TV INPUT (V_line) TV1, TV2, TV3
OUT
5,6,7,8,
Analog / Digital
2KV
±5v
1KV DC / DC
5v
1KV DC / DC
Connected to 24V
Connected to5V (PORT1)
Connected to (90..690V)
Connected to 5V CPU
Legend
max 230 Vac
1KV
500V
1KV
1KV
max 690 Vac SSR
SSR1, SSR2, SSR3
POWER CONTROLLER OUT 1,2,3 4KV
OUT 9, 10 RELÈ

7
80999D_MHW_GFW 400-600A_07-2020_ENG
2.4 Dimensions
SINGLE-PHASE GFW
GFW DUAL-PHASE
GFW THREE-PHASE
Figure 1

880999D_MHW_GFW 400-600A_07-2020_ENG
2.5 temPlate Dimensions
2.6 installation
Attention: respect the minimum
distances shown in gure 3 to provide
adequate air circulation.
Figure 2
Figure 3
65.0
339.0
65.0
M5(X4 FORI)
5.2
339.0
65.0
M5(X8 FORI)
5.2
31.5
65.0 65.0 65.0
339.0
65.0
M5(X12 FORI)
5.2
31.5
65.0
31.5
65.0
15.8
15.8
15.8
6.0 6.0 6.0
GFW MASTER GFW BI-PHASE GFW THREE-PHASE

9
80999D_MHW_GFW 400-600A_07-2020_ENG
2.7 short circuit Protection
Products listed in table "UL508 SCCR FUSES TABLE " are suitable for use on a circuit capable of delivering not more than 100,000
A rms Symmetrical Amperes, 600 Volts maximum when protected by fuses.
Use fuses only
According to UL508, test at 100.000A were carried out with class J fuses rated xxxA (refer to table "SCCR fuse protection table" to
details of the current size fuses for the fuse).
After a shortcircuit the functioning of the device is not guaranteed.
To guarantee the functioning of the device after the short circuit, it is recommend the use of extra rapid fuses as in table "EXTRARAPID
FUSES".
ATTENZIONE: The opening of the branch-circuit protective device may be an indication that a fault has been interrupted. To reduce
the risk of re or electric shock, current-carrying parts and other components of the device should be examined and replaced if
damaged. If burnout of the device occurs, the complete device must be replaced or equivalent.
SCCR RMS SYM
100KA / 600V
UL508 SCCR FUSES TABLE
Model Conguration "Short circuit
current [Arms]"
"Max fuse
size [A]" Fuse Class "Max Voltage [VAC]"
GFW 400 1PH or 2PH or 3PH 100.000 400 J600
GFW 500 1PH or 2PH or 3PH 100.000 600 J600
GFW 600 1PH or 2PH or 3PH 100.000 600 J600
The fuses on the above table are representative of all the fuses of the same class with lower current ratings

10 80999D_MHW_GFW 400-600A_07-2020_ENG
2.8 General DescriPtion Gfw
1 Auxiliary output connector
2 Relay output connector
3 24V digital input connector and power supply
4 Dip Switch conguration
5 Rotary Switch (address)
6 3 analogue input connector
7 Connector for GFW-OP keypad
8 24 V fan power supply output connector
9 Load terminal (pre-split protection grid)
10 Cover on internal fuse protection and Line / Load connections
11 Line terminal (pre-split protection grid)
12 V-load measurement connector
13 V-line measurement connector
14 3-way external TA input connector
15 Port2 Fieldbus connectors and led
16 Operating status led
17 Port1 RS 485 Modbus RTU
Figure 4

11
80999D_MHW_GFW 400-600A_07-2020_ENG
PERIODIC CLEANING
Every 6-12 months (depending on the dust level of the installation) blow a compressed air jet downward through the upper rectangular
cooling grilles (on the side opposite the fan).
This will clean the internal heat dissipater and the cooling fan.
IN CASE OF OVERHEAT ALARM
If periodic cleaning does not eliminate the problem, perform the following operations after rst checking that the GFW has been turned
off and cut off from the electrical power supply to ensure the operator’s safety:
a. Extract the 24V power supply connector from the fan.
b. Use a crosshead screwdriver to unscrew the two screws holding the fan in place (see drawing ).
c. Extract the fan, complete with its protective grid, and inspect.
d. Clean or replace the fan.
CAUTION: before putting the fan back into the product, make sure that the arrow showing the direction of the air ow on the fan
is pointing toward the dissipater.
e. Insert the fan, complete with its protective grid, centring it on the two reference pins.
f. Screw in the two screws xing it in place with a crosshead screwdriver, tightening to a torque of 0.8 Nm.
g. Insert the fan’s 24V power supply connector.
h. Turn on the power to the product and check that the fan turns in the right direction.
Figure 5
2.9 cleaninG/checkinG or rePlacinG the fan

12 80999D_MHW_GFW 400-600A_07-2020_ENG
CUT OFF POWER BEFORE AND DURING FUSE SUBSTITUTION PROCEDURE
-Unscrew the screw (1) holding the cover in place
-Remove the cover, in the direction shown by the arrow (2).
-The fuse is revealed (3).
-Slacken the two bolts xing the fuse in place with a No.19 spanner (GFW 500/600A) or a No.17 spanner (GFW 400A).
-There is no need to remove the bolts, as the fuse is pulled out of its housing as shown by the arrows (5).
-Insert the new fuse as shown by the arrows (6).
CAUTION: the washer must be between the bolt and the copper strap (NOT under the fuse).
-Tighten the two nuts with a No. 19 spanner (GFW 500/600A) or a No. 17 spanner (GFW 400A), to a torque of 12 Nm.
-Put the cover back in place, pinning down the top part rst (be careful to hook it on the tooth as shown in the gure).
-Fix the cover in place, tightening the screw in its housing (1).
2.10 rePlacinG the internal fuse (oPtional)
Figure 6
Figure 7
Figure 8

13
80999D_MHW_GFW 400-600A_07-2020_ENG
DO AS FOLLOWS:
a. Slacken the screws (1) on the front piece and remove the front piece (2).
b. Slacken the screws (3) on the CPU cover and remove the cover (4).
c. Insert the Fieldbus interface card (5) in the connectors provided on the supporting card (6). Check that the card is inserted
correctly.
d. Put the CPU cover (4) back in place and x it in place by tightening the screws (3).
e. Use the new front piece (2) supplied with the Fieldbus card (or open the pre-fractured parts present on the product’s original front
piece) and x it in place by tightening the screws (1).
WARNING:
Use ESD guards to avoid to damage the internal HW with electrostatic discharges.
Figure 9
2.11 carD insertion for fielDbus interface

14 80999D_MHW_GFW 400-600A_07-2020_ENG
3 • ELECTRICAL CONNECTIONS
3.1 Power connections
GFW 400-500-600A
RECOMMENDED WIRE GAUGES
GFW
CURRENT
LEVEL
TERMINAL TYPE CABLE / SECTION
TYPE RAIL / SECTION
TERMINAL TYPE
CABLE / RAIL
TIGHTENING /
TOOL TORQUE
Wiring
notes
400A 1/L1, 2/T1 Single cable - 300 mm2
(600Kcmil)
Wire crimped at terminal tube
Cembre A60-M12
N. 1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 50 Nm (**) (***)
FIG. A
400A 1/L1, 2/T1 Double cable - 2 x 95 mm2
(3/0 AWG)
Wire crimped at terminal tube
Cembre A19-M10
N. 2 Bolts M10x25mm UNI 5739
hex head wrench n. 17
Pair: 40 Nm (***)
FIG. B
400A 1/L1, 2/T1 Double cable - 2 x 95 mm2
(3/0 AWG)
Wire stripped for 30mm
inserted in ILSCO AU-350 lug
(Accessory)
N. 1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 50 Nm
(*) see note
FIG. C
400A 1/L1, 2/T1
Copper rail
(W= width, H = height)
W = 40 32 24 mm
H = 2 2 3 mm
Insulated copper rail with
terminal non-insulated for L=
60-65mm max
N. 1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 50 Nm
FIG. D
400A PE Cable 95 mm2
(3/0 AWG)
Wire crimped at terminal tube
Cembre A19-M10
N. 1 Bolt M10x20mm UNI 5739
hex head wrench n. 17
Pair: 40 Nm (***)
FIG. E
500 A 1/L1, 2/T1 Double cable - 2 x 120 mm2
(250 Kcmil)"
Wire crimped at terminal tube
Cembre A24-M10
N. 2 Bolts M10x25 mm UNI 5739
hex head wrench n. 17
Pair: 40 Nm
500 A 1/L1, 2/T1 Double cable - 2 x 120 mm2
(250 Kcmil)"
Wire stripped for 30mm
inserted in ILSCO AU-350 lug
(Accessory)
N.1 Bolt M12x25 mm UNI 5739
hex head wrench n. 18
Pair: 50 Nm (*)
500 A 1/L1, 2/T1
Copper rail
(W= width, H = height)
W = 40 32 24 mm
H = 3 4 5 mm
Insulated copper rail with
terminal non-insulated for
L= 60-65 mm max
N. 1 Bolt M12x25 mm UNI 5739
hex head wrench n. 18
Pair: 50 Nm
500 A PE Cable 120 mm2
(250 Kcmil)
Wire crimped at terminal tube
Cembre A24-M10
N. 1 Bolt M10x20 mm UNI 5739
Chiave esagonale n. 17
Pair: 40 Nm
600A 1/L1, 2/T1 Double cable - 2 x 185mm2
(350 Kcmil)
Wire crimped at terminal tube
Cembre A37-M10
N. 2 Bolts M10x25mm UNI 5739
hex head wrench n. 17
Pair: 40 Nm (***)
FIG. F
600A 1/L1, 2/T1 Double cable - 2 x 185mm2
(350 Kcmil)
Wire stripped for 30mm
inserted in ILSCO AU-350 lug
(Accessory)
N.1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 50 Nm
(*) see note
FIG. G
600A 1/L1, 2/T1
Copper rail
(W= width, H = height)
W = 50 40 32 mm
H = 4 4 5 mm
Insulated copper rail with
terminal non-insulated for L=
60-65mm max
N.1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 50 Nm
FIG. H
600A PE Cable 185mm2
(350 Kcmil)
Wire crimped at terminal tube
Cembre A37-M10
N. 1 Bolt M10x20mm UNI 5739
hex head wrench n. 17
Pair: 40 Nm (***)
FIG. E
400 / 500 /
600 A J6, J7 0.25 … 2.5mm2cable
23 …14 AWG
Cable peeled for 8mm or with
a tag terminal
0.6 …0.6 Nm / 0.6 x 3.5mm slotted
screwdriver
(*) NOTE: Wires on the ILSCO accessory must be tightened with a hex head wrench n. 8. Torque: 30 Nm.
(**) NOTE: Use the IP20 grid of ILSCO accessory code F067432.
(***) NOTE: use only UL cable terminals with their stapler

15
80999D_MHW_GFW 400-600A_07-2020_ENG

16 80999D_MHW_GFW 400-600A_07-2020_ENG
3.2 functions of leDs inDicators
Table 4 Description of LEDs
Led Description color color
RN Run - ashing during normal operation green
ER Error status: activated in the presence of an alarm red
DI1 State digital input 1 yellow
DI2 State digital input 2 yellow
O1 State output Out 1 yellow
O2 State output Out 2, only with GFW 2ph o 3 ph products yellow
O3 State output Out 3, only with GFW 3 ph products yellow
BUTTON State HB key yellow
Leds State
LED status refers to the corresponding parameter, with the following special cases:
-LED RN (green) on: hotkey functionality
-LED RN (green) + LED ER (red) both ashing rapidly: autobaud in progress
-LED ER (red) ashing: temperature alarm ((OVER_HEAT or TEMPERATURE_SENSOR_BROKEN) or alarm of
-SHORT_CIRCUIT_CURRENT or SSR_SAFETY or FUSE_OPEN (only for singlephase conguration).
-LED ER (red) + LED Ox (yellow) both ashing: HB alarm or POWER_FAIL in zone x
-All LEDs ashing rapidly: ROTATION123 alarm (only for threephase conguration)
-All LEDs ashing rapidly except LED DI1: jumper conguration not provided
-All LEDs ashing rapidly except LED DI2: 30%_UNBALANCED_ERROR alarm (only for threephase conguration)
-All LEDs ashing rapidly except LED O1: SHORT_CIRCUIT_CURRENT alarm (only for threephase conguration)
-All LEDs ashing rapidly except LED O2: TRIPHASE_MISSING_LINE_ERROR alarm (only for threephase conguration)
-All LEDs ashing rapidly except LED O3: SSR_SAFETY alarm (only for threephase conguration)
-All LEDs ashing rapidly except LED BUTTON: FUSE_OPEN alarm (only for threephase conguration)
Table 5 Description of Rotary Switches
Switch Description
x10
Denes address of module 00...99
(in case of GFX compatible mode ( dip switch 7= ON), this address is attributed to the GFW-M module;
the expansions, if present, will have address +1 ( GFW-E1) and address +2 ( GFW-E2)) Hexadecimal
combinations are reserved.
x1

17
80999D_MHW_GFW 400-600A_07-2020_ENG
3.3 DescriPtion inPut/outPut
Figure 10
+
-
3/L1
5/T1
Top View Bottom View
4/L2
(Ref. V_Line)
6/T2
(Ref. V_Load)
PE
Ground protection
J5
Connector 3 inputs
external CT (optional)
1/L1
Power line input
(DIN or cable)
J7
V-Load
Connector (optional)
J6
V-Line
Connector
Front View
RUN.........(Green)
ERROR.....(Red)
DI1...........(Yellow)
DI2...........(Yellow)
01.............(Yellow)
02.............(Yellow)
03.............(Yellow)
BUTTON...(Yellow)
J8-J9
PORT1
RS 485 Modbus RTU2
RJ11 connector
Dip Switch serial line
+INA1
GND
EARTH
+INA2
+INA3
GND
Out + 5V potentiometer
J4
3 analog inputs
connector
Magnetic area
keypad fixing
GFW-OP
HB Button
DipSwitch
Load configuration
RotarySwitch
Modbus address
FIELDBUS
optional
8 LED STATUS
(configurable)
+24Vdc supply
GND
EARTH
+INDIG1
+INDIG2
+INDIG3
+INDIG4
GND
J3
Power connector and
Digital Inputs 24V
C (OUT9)
NC
NO
C (OUT10)
NC
NO
COM
OUT5
OUT6
OUT7
OUT8
J1
Auxiliary outputs
connector (optional)
J2
Relay outputs connector
OUT9-OUT10
TA1+
TA1 -
TA2+
TA2 -
TA3+
TA3 -
2/T1
"Load" Output
connection
(DIN or cable)
DB9
Connector
for Keypad
GFW-OP
PORT1
PORT2
PORT3

18 80999D_MHW_GFW 400-600A_07-2020_ENG
3.3.1 Connector J1 outputs 5...10
Connector J1 will be assembled in the presence of auxiliary outputs (O5...O8).
Figure 11 Connector J1
Table 6
0.25 - 2.5mm2 23-14AWG
0.25 - 2.5mm2 23-14AWG
OUTPUTS 5...8 Logical (option D) / Analogue (option W)
Logic outputs: 18...36Vdc, max 20mA
Continuous outputs: voltage (default) 0/2...10V, max 25mA
current 0/4...20mA, max 500Ω
Figure 12 Wiring diagram for logical/analogue outputs
LOAD LOAD LOAD LOAD
1
5
4
3
2O5
O6
O7
O8
Com 5¸8
V
I
++++
Table 7
PIN Name Decription
Logic Analogue
1Com 5-8 Outputs common (-)
2 O5 Output 5 (+)
3O6 Output 6 (+)
4O7 Output 7 (+)
5O8 Output 8 (n.c.)
RELAY OUTPUTS 5...8 (option R)
Outputs Out 5...8 relay Ir = 3A max, NO
V = 250V/30Vdc cosφ = 1; I = 12A max
Figure 13 Connection scheme for relay outputs
LOAD
O8
Com 5¸8
Ir
I
O7
O6
O5
2
1
3
4
5
V
LOAD LOAD LOAD
Table 8
PIN Name Decription
1Com 5-8 Common outputs
2 O5 Output 5
3O6 Output 6
4O7 Output 7
5O8 Output 8

19
80999D_MHW_GFW 400-600A_07-2020_ENG
3.3.2 Connector J2 outputs 9, 10
Figure 14 Connector J2
Table 9
0.25 - 2.5mm2 23-14AWG
0.25 - 2.5mm2 23-14AWG
RELAY OUTPUTS 9, 10
Outputs Out 9, 10 relay 5A max, Relay with exchange contact (C, NC, NO)
V = 250V/30Vdc cosφ = 1; I = 5A max
Figure 15 Connection scheme for relay outputs
Table 10
PIN Name Description
1COut 9 Out 9 - Common contact
2NC Out 9 Out 9 - Normally closed contact
3NO Out 9 Out 9 - Normally open contact
4 C Out 10 Out 10 - Common contact
5 NC Out 10 Out 10 - Normally closed contact
6NO Out 10 Out 10 - Normally open contact

20 80999D_MHW_GFW 400-600A_07-2020_ENG
3.3.3 Connector J3 Power supply and digital inputs.
Figure 16
Table 11
0.25 - 2.5mm2 23-14AWG
0.25 - 2.5mm2 23-14AWG
Table 12
PIN Name Description
1 +24Vdc 24 Vdc supply
2GND
3 Earth Earth EMC
4+ INDIG1 Digital input 1 (5 … 32Vdc) congurable NPN / PNP
5+ INDIG2 Digital input 2 (5 … 32Vdc) congurable NPN / PNP
6+ INDIG3 Digital input 3 (5 … 32Vdc) congurable NPN / PNP
7+ INDIG4 Digital input 4 (5 … 32Vdc) congurable NPN / PNP
8GND GND common
Figure 17 Connection scheme
Wiring diagram with PNP inputs Wiring diagram with NPN inputs