gefran GFW Series User manual

GFW400...600A
MODULAR POWER
CONTROLLER
INSTALLATION AND OPERATION MANUAL
Side 1 Installation and Connection
Electrical connections
Side 2 Technical-Commercial information
General Information
Dimensions
Fixing/Installation
Derating curves
code 80498A- 05-2019 - ENG
RECOMMENDED WIRE GAUGES
INSTALLATION AND CONNECTION
CONNECTIONS
GEFRAN spa
via Sebina, 74 - 25050 Provaglio d’Iseo (BS)
Tel. [phone] - fax [phone]- Internet: http://www.gefran.com
ELECTRICAL CONNECTIONS
+
-
3/L1
5/T1
PORT1
PORT2
PORT3
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 RTU
2 RJ11 connector
Dip Switch serial line
+INA1
GND
EARTH
+INA2
+INA3
GND
Out + 5V potentio meter
J4
3 analog inputs
connector
Magnetic area
keypad xing
GFW-OP
HB Button
DipSwitch
Load conguration
RotarySwitch
Modbus address
FIELDBUS (optional)
8 LED STATUS
(congurable)
+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
REplaCINg ThE INTERNal FuSE (OpTIONal)
CUT OFF POWER BEFORE AND DURING
FUSE SUBSTITUTION PROCEDURE
- Undo the cover fastening screw (1)
- Remove the cover following the movement indicated by
the arrow (2)
- In this way the fuse is discovered (3)
- Slacken the two bolts fixing 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 indicated by the arrows (6)
WARNING: 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 first
(be careful to hook it on the tooth as shown in the figure).
- Fasten the cover by the specific screw in side (1)
GFW
CURRENT
LEVEL
TERMINAL
TYPE CABLE /
SECTION
TYPE RAIL / SECTION
TERMINAL TYPE
CABLE / RAIL
TIGHTENING /
TOOL TORQUE
400 A 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: 442.5 lb.in. (50 N-m) (**) (***)
400 A 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: 354.0 lb.in. (40 N-m) (***)
400 A 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: 442.5 lb.in. (50 N-m) (*) see note
400 A 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: 442.5 lb.in. (50 N-m)
400 A 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: 354.0 lb.in. (40 N-m) (***)
500 A 1/L1, 2/T1 Double cable
2 x 120 mm2(350 kcmil)
Wire crimped at terminal tube
Cembre A24-M10
N. 2 Bolts M10x25mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
500 A 1/L1, 2/T1 Double cable
2 x 120 mm2(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: 442.5 lb.in. (50 N-m) (*) see note
500 A 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: 442.5 lb.in. (50 N-m)
500 A PE Cable 185 mm2
(350 kcmil)
Wire crimped at terminal tube
Cembre A24-M10
N. 1 Bolt M10x20mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
600 A 1/L1, 2/T1 Double cable
2 x 185 mm2(350 kcmil)
Wire crimped at terminal tube
Cembre A37-M10
N. 2 Bolts M10x25mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
600 A 1/L1, 2/T1 Double cable
2 x 185 mm2(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: 442.5 lb.in. (50 N-m) (*) see note
600 A 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: 442.5 lb.in. (50 N-m)
600 A PE Cable 185 mm2
(350 kcmil)
Wire crimped at terminal tube
Cembre A37-M10
N. 1 Bolt M10x20mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
400 / 500 /
600 A J6, J7 Cable 0.25 … 2.5 mm2
23 …14 AWG
Cable peeled for 8mm or with a tag
terminal
4.425 .... 5.310 lb.in. (0.5 ... 0.6 N-m) /
0.6 x 3.5mm slotted screwdriver
(*) NOTE: Wires on the ILSCO accessory must be tightened with a hex head wrench n. 8. Torque: 275 lb.in. (31 N-m).
(**) NOTE: Use the IP20 grid of ILSCO accessory code F067432.
(***) NOTE: use only UL cable terminals with their stapler
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.
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 specific
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.
NOTES ON ELECTRICAL SAFETY AND
ELECTROMAGNETIC COMPATIBILITY:
CE: Conformity EMC (electromagnetic
compatibility) conformity) in compliance with
Directive 2014/30/EU and following modifications.
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.
LV (low voltage) conformity in compliance with
Directive 2014/35/EU.
EMC conformity has been verified with the
connections indicated on table 1 (see user’s manual).
RECOMMENDATIONS FOR CORRECT
INSTALLATION FOR PURPOSES OF EMC
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 she- athing.
• 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 filters.
• The power supply lines must be separate from
instrument input and output lines.
• Supply from Class II or from limited energy
source.
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 outside circuits must be doubly isolated.
• 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.
- use braided and shielded cables, with sheathing
grounded at a single point.
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)
• 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 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).
• Suitable for use on a circuit capable of delivering not
more than 100,000A RMS Symmetrical Amperes,
600 Volts maximum when protected by class J fuses
rated xxxA. (Refer to the *SCCR fuse protection table
this report for the details of the current size fuses for
each model)
• Use fuses only.
ATTENTION: The opening of the branch-circuit
protective device may be an indication that a fault
has been interrupted. To reduce the risk of fire 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.
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.
Conformity TC RU-C-IT.A/132.B.00422
CSA Conformity C/CSA/US CoFC no. 70002856
The device conforms to European Union Directive 2014/30/EU and 2014/35/EU with reference to standards: EN
60947-4-3:2014.
UL Conformity C/UL/US le no. E243386 vol. 1 sez. 5
SCCR RMS SYM
100KA / 600V
Short Circuit Current Rating 100KA / 600V according to UL 508

TECHNICAL CHARACTERISTICS / GENERAL DATA
POWER (SOLID-STATE RELAY)
CATEGORY OF USE
(Tab. 2 EN60947-4-3)
AC 51 resistive or low inductance loads
AC 55b short wave infrared lamps (SWIR)
AC 56a transformers, resistive loads with high temperature coefcient
Trigger mode PA - load control via adjustment of ring phase angle
ZC - Zero Crossing with constant cycle time (settable in range 1-200s)
BF - Burst Firing with variable cycle time (GTT) optimized minimum.
HSC - Half Single Cycle corresponds to Burst Firing that includes ON and OFF half-
cycles.
Useful for reducing icker with short-wave IR loads (applied only to calibrate each time
you change feedback mode)
Feedback mode V, V2: Voltage feedback: proportional to RMS voltage value on load
to compensate possible variations in line voltage.
I, I2: Current feedback: proportional to RMS current value on load to compensate
variations in line voltage and/or variations in load impedance.
W: Power feedback: proportional to real power value on load to compensate variations
in line voltage and/or variations in load impedance.
You have to calibrate each time you change feedback mode.
Max rated voltage 480Vac 600Vac 690Vac
Work voltage range 90…530Vac 90…660Vac 90...760Vac
Non-repetitive voltage 1200Vp 1600Vp 1600Vp
Rated frequency 50/60Hz auto-determination
Critical Dv/dt with output deactivated 1000V/µsec
Held nominal voltage of on the
impulse 4KV
Nominal current for short circuit
condition 5KA
Protection RC, extrarapid fuses
Rated current AC51
non-inductive or slightly inductive
loads, resistance furnaces
GFW 400 Nominal current 400 Arms @50°C in continuous service
Non-repetitive overcurrent t=10ms: 8,000 A
Melting fuse I²t: 320,000 A²s
GFW 500 Nominal current 500 Arms @50°C in continuous service
Non-repetitive overcurrent t=10ms: 15,000 A
Melting fuse I²t: 1,125,000 A²s
GFW 600 Nominal current 600 Arms @50°C in continuous service
Non-repetitive overcurrent t=10ms: 15,000 A
Melting fuse I²t: 1,125,000 A²s
NOTE (for all models)
Minimum load controllable: 5 % of product current rated level.
Thermic Dissipation GFW models dissipate thermic power based on load current:
Pdissipation = I_load_Arms * 1.3V (W)
For models with integrated fuse, also consider dissipated power at rated current shown
on the fuse table
Rated current AC56A permitted
trigger modes: ZC, BF with
DT (Delay Triggering),PA with
softstart
Derating: 20% of rated current value.
GFW 400 / 500 / 600A
100
200
300
400
500
600
700
6050 T(°C)
I(A)
GFW SINGLE-PHASE
Lateral view
with keypad
GFW DUAL-PHASE
(Master + 1 Expansion)
GFW THREE-PHASE
(Master + 2 Expansions)
Model
EXTRARAPID FUSES
Size
I²t
Code
Format
Model
Code
Power
Dissipated @ In
GFW 400 630 A
310000 A2s FUS-630S PC32UD69V630TF
338213 60 W
GFW 500 1000 A
970000 A2s FUS-1000 PC33UD69V1000TF
338160 50 W
GFW 600 1000 A
970000 A2s FUS-1000 PC33UD69V1000TF
338160 60 W
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 J 600
GFW 500 1PH or 2PH or 3PH 100.000 600 J 600
GFW 600 1PH or 2PH or 3PH 100.000 600 J 600
The fuses on the above table are representative of all the fuses of the same class with lower current ratings
DIMENSIONS
DERATING CURVES
GENERAL DATA
Power supply GFW 1PH-400/500/600A: 24 Vdc ± 10% max 38W
GFW 2PH-400/500/600A: 24 Vdc ± 10% max 66W
GFW 3PH-400/500/600A: 24 Vdc ± 10% max 94W
Signals Eight led:
RN (Green) run state of CPU
ER (Red) error signal
DI1, DI2, (Yellow) state of digital inputs INDIG1, INDIG2
O1,O2,O3 (Yellow) state of power control
BT (Yellow) state key HB
Protection IP20
Work/storage temperature 0…50°C (refer to dissipation curves) / -20 °C - +85 °C
Relative humidity 20…85% Ur non-condensing
Ambient conditions for use indoor use, altitude up to 2000m
Installation panel with screws
Installation requirements Installation category II, pollution level 2, double isolation.
Max. temperature of air surrounding device 50°C for temperature >50°C refer at derating
curves Device type: “UL Open Type
Weight Model with
internal fuse GFW-1PH GFW-2PH GFW-3PH
GFW 400 8 kg 15.5 kg 22.5 kg
GFW 500/600 11 kg 21 kg 31 kg
Overvoltage protection: only for installation in Canada, the device must be protected by a protective device from external overvoltage,
R/C (VZCA2/8) or CSA Certied.
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 filters are required in PA mode (Phase Angle, i.e., SCR trigger with phase angle modulation). The filter model and current
level depend on the configuration and load used. The power filter MUST by connected as close as possible to the GFW. You
can use a filter connected between the power line and GFW or an LC group connected between the GFW output and the load.
Graphic simbol
Indicates contents of sections, general instructions, notes, and other points to which the reader’s attention needs to
be called.
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 risk to the user’s safety due to high voltage at the points indicated.
Attention: respect the minimum
distances shown in figure to provi-
de adequate air circulation.
- Panel mounting and cut-out dimensions
- Installation
GFW Single-phase GFW Dual-phase
GFW Three-phase
FIXING / INSTALLATION
Minimum distance <
100 mm