gefran GFW ADV Instruction sheet

180963B_MSW_GFW_11-2012_ENG
ATTENTION!
This manual is an integral part of the product,
and must always be available to operators.
This manual must always accompany the pro-
duct, including if it is transferred to another user.
Installation and/or maintenance workers MUST
read this manual and scrupulously follow all of the in-
structions in it and in its attachments. GEFRAN will not
be liable for damage to persons and/or property, or to
the product itself, if the following terms and conditions
are disregarded.
The Customer is obligated to respect trade
secrets. Therefore, this manual and its attachments
may not be tampered with, changed, reproduced,
or transferred to third parties without GEFRAN’s
authorization.
CONFIGURATION AND
PROGRAMMING MANUAL
Software version: 2.0x
code: 80963B - 11-2012 - ENG
GFW adv
ADVANCED MODULAR POWER CONTROLLER
This document is the property of GEFRAN and may not be reproduced or transferred to third parties without authorization.
This document supplements the following manuals:
- Instructions and warnings for GFW

280963B_MSW_GFW_11-2012_ENG

380963B_MSW_GFW_11-2012_ENG
TABLE OF CONTENTS AND SUMMARIES
TABLE OF CONTENTS AND SUMMARIES .....................3
INTRODUCTION.................................................................4
FIELD OF USE ..............................................................4
CHARACTERISTICS OF PERSONNEL ........................4
STRUCTURE OF THIS MANUAL...................................5
INSTRUMENT ARCHITECTURE........................................6
SERIAL COMMUNICATION (MODBUS) ........................7
CONNECTION................................................................8
INPUTS ..............................................................................9
ANALOG INPUT .............................................................9
MAIN INPUT ................................................................10
CURRENT VALUE ON LOAD ......................................14
VOLTAGE VALUE ON LOAD........................................17
LINE VOLTAGE VALUE................................................17
POWER ON LOAD ......................................................21
AUXILIARY ANALOG INPUTS (LIN/TC).......................23
DIGITAL INPUTS ..........................................................26
USING A FUNCTION ASSOCIATED WITH DIGITAL
INPUT AND VIA SERIAL...............................................27
USING A FUNCTION OF DIGITAL INPUT 1
TO ENABLE AT SOFTWARE ON .................................28
ALARMS ...........................................................................29
GENERIC ALARMS AL1, AL2, AL3 e AL4 ....................29
LBA ALARM (Loop Break Alarm) .................................34
HB ALARM (Heater Break Alarm)................................35
SBR - ERR ALARMS
(probe in short or connection error) ..............................39
Power Fault ALARMS
(SSR_SHORT, NO_VOLTAGE and NO_CURRENT) ...40
Overheat Alarm .............................................................41
SHORT CIRCUIT CURRENT ALARM ..........................41
FUSE OPEN ALARM ....................................................41
OUTPUTS .........................................................................42
ALLOCATION OF REFERENCE SIGNALS .............42
ALLOCATION OF PHYSICAL OUTPUTS ................44
SETTINGS.........................................................................46
SETTING THE SETPOINT ...........................................46
SETPOINT CONTROL..................................................47
CONTROLS ......................................................................49
PID HEAT/COOL CONTROL ........................................49
AUTOMATIC / MANUAL CONTROL.............................53
HOLD FUNCTION ........................................................53
MANUAL POWER CORRECTION ...............................53
MANUAL TUNING ........................................................54
AUTOTUNING ..............................................................54
SELFTUNING ...............................................................56
SOFTSTART.................................................................57
START MODE...............................................................57
SOFTWARE SHUTDOWN............................................58
OTHER FUNCTIONS........................................................59
FAULT ACTION POWER ..............................................59
POWER ALARM ...........................................................59
SOFTSTART FOR PREHEATING ................................61
HEATING OUTPUT (Fast cycle)...................................61
POWER CONTROL ..........................................................62
SSR CONTROL MODES ..............................................62
FEEDBACK MODALITY ...............................................64
HEURISTIC POWER CONTROL..................................66
HETEROGENEOUS POWER CONTROL....................67
VIRTUAL INSTRUMENT CONTROL................................68
HW/SW INFORMATION....................................................69
INSTRUMENT CONFIGURATION SHEET.......................73
KEYPAD USE ...................................................................92

480963B_MSW_GFW_11-2012_ENG
INTRODUCTION
The modular power controller described in this manual and shown on the cover is a separate unit for the independent
control of a maximum of 3 zones. It offers high applicative exibility thanks to the extended congurability and programmability
of its parameters.
Instrument conguration and programming must be performed with a GFW-OP or a PC connected in USB/RS232/
RS485, with specic GF_eXpress application software.
Since it is impossible to foresee all of the installations and environments in which the instrument may be applied,
adequate technical preparation and complete knowledge of the instrument’s potentials are necessary.
GEFRAN declines all liability if rules for correct
installation, conguration, and/or programming are
disregarded, as well as all liability for systems upline
and/or downline of the instrument.
FIELD OF USE
The modular power controller is the ideal solution for applications in heat treatment furnaces, in thermoformers, in
packaging and packing machines and, in general, in standard temperature control applications. Nevertheless, because it is
highly programmable, the controller can also be used for other applications provided they are compatible with the instrument’s
technical data.
Although the instrument’s exibility allows it to be used in a variety of applications, the eld of use must always conform to the
limits specied in the technical data supplied.
GEFRAN declines all liability for damage of any
type deriving from installations, congurations, or
programmings that are inappropriate, imprudent, or
not conforming to the technical data supplied.
Prohibited use
It is absolutely prohibited:
- to utilize the instrument or parts of it (including software) for any use not conforming to that specied in the technical docu-
mentation supplied;
- to modify working parameters inaccessible to the operator, decrypt or transfer all or part of the software;
- to utilize the instrument in explosive atmospheres;
- to repair or convert the instrument using non-original replacement parts;
- to utilize the instrument or parts of it without having read and correctly understood the technical documentation supplied;
- to scrap or dispose of the instrument in normal dumps; components that are potentially harmful to the environment must be
disposed of in conformity to the regulations of the country of installation.
CHARACTERISTICS OF PERSONNEL
All personnel operating, installing, or doing maintenance on the instrument must be expert, trained, aware and mature,
able to reliably and correctly interpret this manual.
This manual CANNOT make up for cultural or intellectual insufciencies. Therefore, all personnel interacting with the instru-
ment must:
- have adequate education, training, and skills;
- be completely aware of what he/she is doing;
- NOT act in an intentionally self-destructive manner.
All personnel must always use proper methods, instruments, and protective devices to work under safe conditions.
It is forbidden to employ untrained personnel, per-
sons with disabilities, legally disqualied persons,
persons who are not sober, or persons who take
drugs.

580963B_MSW_GFW_11-2012_ENG
STRUCTURE OF THIS MANUAL
This manual was originally written in ITALIAN. Therefore, in case of inconsistencies or doubts, request the original
manual or explanations from GEFRAN.
The instructions in this manual do not replace the safety instructions and the technical data for installation, conguration and
programming applied directly to the product or the rules of common sense and safety regulations in effect in the country of
installation.
For easier understanding of the controller’s basic functions and its full potentials, the conguration and programming parameters
are grouped according to function and are described in separate chapters.
Each chapter has from 1 to 3 sections:
- the rst section presents a general description of the parameters described in detail in the following zones;
- the second section presents the parameters needed for the controller’s basic applications, which users and/or
installers can access clearly and easily, immediately nding the parameters necessary for quick use of the controller;
- the third section (ADVANCED SETTINGS ) presents parameters for advanced use of the controller:
this section is addressed to users and/or installers who want to use the controller in special applications or in applications
requiring the high performance offered by the instrument.
Some sections may contain a functional diagram showing interaction among the parameters described;
- terms used on other pages of the manual (related or supplemental topics) are shown in underlined italics and listed
in the index (linked to IT support).
In each section, the programming parameters are shown as follows:
400*
21 - 29 - 143 tYP. R/W Type of probe, signal, enable, custom
linearization and main scale input
-999 ...999
Scale points 1000
Unless indicated otherwise, these parameters are in decimal format
and represent 16 bit words.
Main Modbus address and additional addresses (if any).
Any second / third Modbus addresses are alternatives to the main address.
The presence of the asterisk near the main address indicates that the parameter is available for every zone; the lack indicates that the
parameter is total to the device.
Mnemonic code (if any)
R read only (read) and/or W (write) attribute
Description
Supplemental data and/or information on the parameter
Setting limits Default value
Supplemental data and/or information
Supplemental data and/or information
dP_S Format
0 xxxx
1 xxx.x
2 xx.xx (*)
Supplemental data and/or
information
68
bit
STATE
DIGITAL INPUT 1
OFF = Digital input 1 off
OFF = Digital input 1 on
Function
R/W These parameters are represented in 1 bit format.

680963B_MSW_GFW_11-2012_ENG
INSTRUMENT ARCHITECTURE
The modular power controller’s exibility permits replacement of previous-version such as GEFLEX (GFX), GFX4
and GFX4-IR instruments without changing the control software in use.
Based on the chosen work mode (see MODBUS SERIAL COMMUNICATION), you can use the instrument in 2 different
modes:
- GFX compatible mode: as if there were at most 3 separate instruments (recommended for retrotting projects and/
or replacement of damaged instruments);
- GFX4/GFW mode: as a single instrument with the same functions as at most 3 separate instruments, but with
possibility of interaction among the various parameters, inputs and outputs (recommended for new projects).
New shared parameters, are accessible for both modes and permit more advanced functions such as:
604 FLt.2 R/W Digital filter for auxiliary input 0.0 ... 20.0 sec 0.1
In addition to having a CUSTOM group of parameters for dynamic addressing, GFX4/GFW mode lets you use a single
communication network node instead of 3 nodes as in GFX compatible mode.
When programming, keep in mind that some of the
addresses (parameters) described in this manual
exist at most 3 times, specied by address node
(ID).
Inputs ID01...
...ID03
Allocation of
outputs
Out1
Out2
Out3
Out5
Out6
Out7
Out8
Out9
Out10
GFX Compatible HARDWARE
SOFTWARE Outputs
Inputs
Inputs
Inputs
Shared
parameters
ID03 Parameters
(**)
ID02 Parameters
(*)
ID01
Parameters
Inputs
ID01
Allocation
of outputs
Out1
Out2
Out3
Out5
Out6
Out7
Out8
Out9
Out10
HARDWARE GFX4/GFW
SOFTWARE Outputs
Inputs
ID01
Allocation
of inputs
ID01
Parameters
------------------------
Custom parameters
Shared parameters
Serial line
Serial line
(*) if GFW_E1 module is present
(**) if GFW_E2 module is present

780963B_MSW_GFW_11-2012_ENG
SERIAL COMMUNICATION (MODBUS)
There are two Modbus addressing modes for variables and conguration parameters:
- GFX compatible
- GFX4/GFW
The modes are selected with dip-switch-7.
GFX-compatible mode (dip-switch-7 =ON)
This lets you uses supervision programs created for Geex modules.
Memory is organized in at most 3 groups:
- Zone 1 for the variables of the module GFW-M
- Zone 2 for the variables of the module GFW-E1
- Zone 3 for the variables of the module GFW-E2
In each zone, the variables and parameters have the same address as a Geex instrument; the value (Cod) set on
the rotary switches corresponds to that of Zone 1; the values in the other zones, if expansions are present, are sequential.
Examples:
if the rotary switches have value 14, node 14 addresses Zone 1 (GFW-M), node 15 Zone 2 (GFW-E1), node 16 Zone 3 (GFW-E2).
The power Ou.P for Zone 1 has address Cod 2, the Ou.P for Zone 2 has address Cod+1, 2, etc...
Parameter out.5, which denes the function of output OUT 5 on the GFW, has address Cod 611.
GFX4/GFW mode (dip-switch-7=OFF)
This lets you optimize the efciency of serial communication by integrating at most 3 zones in the GFW. Memory is
organized in 4 groups: 3 already in GFX-compatible mode, plus one group dened as custom:
- Custom (additional memory map for dynamic addresses)
- Zone 1 for the variables of the module GFW-M
- Zone 2 for the variables of the module GFW-E1
- Zone 3 for the variables of the module GFW-E2
The custom group contains variables and parameters for a maximum of 120 words. The meaning of these words can
be changed.
There is a single value (Cod) set on the rotary switches; i.e., one for each GFX4/GFW instrument. To access the data
in each zone, simply add an offset to the address (+1024 for Zone 1, +2048 for Zone 2, +4096 for Zone 3).
Words in the custom group have addresses 0,...,119. The variables and parameters are dened by default. At ad-
dresses 200,...,319 we have words containing the value of the address of the corresponding variables or parameters. These
addresses can be changed by the user, offering the ability to read/write data with multi-word messages structured according
to various supervision requirements.
Protection of Maps 1-2
You have to write the value 99 on addresses 600
and 601 to enable change of the custom group
(addresses 200... 319).
This value is reset at each switch-on.
Examples:
you can access the Ou.P variable in Zone 1 with address Cod, 1+1024 or address Cod, 11 custom variable 12 (address Cod,
211 has value 2+1024);
you can access the Ou.P variable in Zone 2 with address Cod, 2+ 2048 or address Cod, 40 custom variable 41 (address Cod,
240 has value 2+2048);
if you want to read the 3 powers in sequence at the rst 3 addresses, set Cod, 200 = 1026, Cod.201 = 2050, Cod,202 = 4098.

880963B_MSW_GFW_11-2012_ENG
CONNECTION
Each GFW has an optically isolated serial port RS485 (PORT 1) with standard Modbus protocol via connectors J8
and J9 (type RJ10).
You can insert a serial interface (PORT 2). There are various models based on the eld bus required: Modbus, Pro-
bus DP, CANopen, DeviceNet and Ethernet.
This communication port (PORT 2) has the same Cod address as PORT 1.
The parameters for PORT 2 are bAu.2 (select baud-rate) and Par.2 (select parity).
The Cod parameter (read only) shows the value of the node address, settable from 00 to 99 with the 2 rotary switches; the
hexadecimal settings are reserved.
A parameter can be read or written from both communication ports (PORT 1 and PORT 2).
Changing the bAu (select baud-rate) and/or PAr (select
parity) parameters may cause communication failure.
To set the bAu and PAr parameters, you have to run the Autobaud procedure described in the “Instruction and warnings” manual.
Installation of the “MODBUS” serial network
A network typically has a Master that “manages” communication by means of “commands” and Slaves that interpret
these commands.
GFW are considered Slaves to the network master, which is usually a supervision terminal or a PLC.
They are positively identied by means of a node address (ID) set on the rotary switches (tens + ones).
GFW have a ModBus serial (Serial 1) and optional Fieldbus (Serial 2) serial (see order code) with one of the following
protocols: ModBus, Probus, CANopen, DeviceNet, Ethernet, EtherCAT and EthernetIP.
The following procedures are indispensable for the Modbus protocol.
For the remaining protocols, see the specific Geflex Profibus, Geflex CANopen, Geflex DeviceNet, Geflex Ethernet,
GFX4-EtherCAT and GFX4-ETH1 manuals.
GFW modules have the following default settings:
- node address = 0 (0 + 0)
- speed Serial 1 = 19200 bit/s
- parity Serial 1 = none
- speed Serial 2 = 19200 bit/s
- parity Serial 2 = none
You can install a maximum of 99 GFW modules in a serial network, with node address selectable from “01” to “99” in standard
mode, or create a mixed GFW / GFX4 network in GFX compatible mode in which each GFW identies 3 zones with sequential
node address starting from the code set on the rotary switches.
In short, the valid rotary switch settings (tens + ones) are:
- (0 +0) = Autobaud Serial 1
- (B +0) = Autobaud Serial 2
46 (od RDevice identification code 1 ... 99
45 baV R/W Select Baudrate - Serial 1 4
0 1200 bit/s
1 2400 bit/s
2 4800 bit/s
3 9600 bit/s
4 19200 bit/s
5 38400 bit/s
6 57600 bit/s
7 115200 bit/s
Baudrate table
47 par R/W Select parity - Serial 1 0
0 No parity
1 Odd
2 Even
Parity table
626 bav.2 R/W Select Baudrate - Serial 2 4
627 par.2 R/W Select parity - Serial 2 0

980963B_MSW_GFW_11-2012_ENG
INPUTS
ANALOG INPUT
The modular power controller has a analog input with the functionality power retransmission.
FUNCTIONAL DIAGRAM
Probe type
tP.A
Scale limits
HS.A, LS.A
Low pass lter
FLt.A see Control
analog input value
(In.A)
Input signal
Probe type
Scale limits
Offset adjustment
Input lter
Read state
573 tP.A R/W analog input 1
Table of analog input
0 Disable
1 0 ... 10V
2 0 ... 5V/Potentiometer
3 0 ... 20mA
4 4 ... 20mA
574 LS.A R/W Minimum scale limit
analog input -100,0...200,0 0,0
577 oFS.A R/W Offset correction for analog input -99,9...99,9 0,0
576 Flt.A R/W Low pass digital filter
analog input 0,0...20,0 sec 0,1
572 In.A RValue of the ingegneristico reading
analog input
575 kS.A R/W Maximum scale limit
analog input LS.A...200,0 100,0
ADVANCED SETTINGS

10 80963B_MSW_GFW_11-2012_ENG
MAIN INPUT PID
The modular power controller has one main input (IN1) to control, to which you can connect temperature sensors
(thermocouples and RTD), linear sensors or custom sensors to acquire process variable (PV) values.
These type of input is optional.
To congure, you always have to dene the type of probe or sensor (tYP), the maximum and minimum scale limit
(Hi.S – Lo.S) for the process variable value, and the position of the decimal point (dP.S).
If the sensor is a thermocouple or resistance thermometer, the minimum and maximum limits can be dened on the specic
scale of the sensor. These limits dene the width of the proportional control band and the range of values settable for the
setpoint and alarm setpoints.
There is a parameter to correct the offset of the input signal (oF.S): the set value is algebraically added to the read
of the process variable.
You can read the state of the main input (Err) in which an input error is reported: when the process variable goes
beyond the upper or lower scale limit, it assumes the value of the limit and the corresponding state reports the error condition:
Lo = process variable < minimum scale limit
Hi = process variable > maximum scale limit
Err = Pt100 in short circuit and input value below minimum limit,
4...20mA transmitter interrupted or not powered
Sbr = Tc probe interrupted or input value above maximum limit
If noise on the main input causes instability of the acquired value, you can reduce its effect by setting a low pass
digital lter (Flt). The default setting of 0.1sec is usually sufcient.
You can also use a digital lter (Fld) to increase the apparent stability of the process variable PV; the lter introduces
a hysteresis on its value: if the input variation remains within the set value, the DPV value is considered unchanged.