gefran GFW-Xtra User manual

GFW-Xtra
MODULAR POWER CONTROLLER WITH
OVERCURRENT PROTECTION
INSTALLATION AND OPERATION MANUAL
Side 1 Installation and Connection
Electrical connections
Side 2 Technical-Commercial information
General Information
Dimensions
Fixing/Installation
Derating curves
code 80314A - 07/2015 - ENG
RECOMMENDED WIRE GAUGES
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.
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 89/336/
CEE 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 2006/95/CE.
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 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 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 iso-
lated from voltage.
Appropriate devices must be provided: fuses or automatic switches to protect power lines.
• 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
- 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 ).
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.
ConneCtions
This device conforms to European Union Directive 2004/108/CE e 2006/95/CE with refe-
rence to generic standards: EN 60947-4-3 (product) EN 61010-1 (safety)
GEFRAN spa
via Sebina, 74 - 25050 Provaglio d’Iseo (BS)
Tel. [phone] - fax [phone]- Internet: http://www.gefran.com
ELECTRICAL CONNECTIONS
GFW
CURRENT
LEVEL
TERMINAL WIRE GAUGE TERMINAL TYPE TIGHTENING /
TOOL TORQUE
40A 1/L1, 2/T1 10 mm2
7 AWG
Wire stripped for 25 mm or
with crimped pre-insulated
terminal tube
CEMBRE PKC1018
5 Nm /
Flat-head screwdriver
tip 1 x 5.5 mm
60A 1/L1, 2/T1 16 mm2
5 AWG
Wire stripped for 25 mm or
with crimped pre-insulated
terminal tube
CEMBRE PKC1618
5 Nm /
Flat-head screwdriver
tip 1 x 5.5 mm
100A 1/L1, 2/T1, 35 mm2
2 AWG
Wire stripped for 25 mm or
with crimped pre-insulated
terminal tube
CEMBRE PKC35025
5 Nm /
Flat-head screwdriver
tip 1 x 5.5 mm
---
3/L2
(Ref. Vline)
4/T2
(Ref. Vload)
0.25 ...2.5 mm2
23...14 AWG
Wire stripped for 8 mm
or with tag terminal
0.5 ... 0.6 Nm /
Flat-head screwdriver
tip 0,6 x 3.5 mm
Note: Cables must be copper “Stranded Wire” or “Compact-Stranded Wire” type with maximum operating
temperature 60/75°C
mV / TC input
(optional)
Top View
(Ref. V_load) 4 / T2
J 10
3 / L2 (Ref. V_line)
GFW-OP
keypad
connector
Address x 10
Address x 1
Line / load voltage
connector
Protection
fan
1 / L1
“Line”
Connection
1 / L1
“Line”
Connection
Screw front cover
(allows access to fuse)
Magnetic area
GFW-OP
(only GFW-M
model)
IN2
IN3
IN4
IN5
J4
2 / T1
“Load”
Connection
2 / T1
“Load”
Connection
2 / T1
“Load”
Connection
IN1- Analog
input connector
PID (optional)
INA- Control
analog
input connector
Address Rotary
Switch
Key HB
Digital input
Status Led
Supply
Outputs
Optional outputs
COM (OUT 5 - 8)
OUT 5
OUT 6
OUT 7
OUT 8
OUT 9 (Relay N.O.)
OUT 10 (Relay N.O.)
+24 vdc
GND-SUPPLY
EARTH
EARTH
I1 -
I1 +
IN1 (RTD)
+INDIG 1
+INDIG 2
+INDIG 3 (PWM
input)GND - INDIG
RUN............(green)
ERROR.......(red)
DI1..............(yellow)
DI2..............(yellow)
01................(yellow)
02................(yellow)
03................(yellow)
BUTTON.....(yellow)
J1
J2
J3
J5
J6
OUT +5 V (Potentiometer)
+ IN
SHUNT - mA
GND - INPUT
Low view
Without option
Fieldbus
Low view
With option
Fieldbus
Protection
fan
J7
fan power
supply
J7
fan power
supply
Connector board
Fieldbus PORT 2 (optional)
J8, J9
Connector RJ10
serial RS485
Modbus (PORT 1)
J8, J9
Connector RJ10
serial RS485
Modbus (PORT 1)
Dip Switch
serial line
Dip Switch
serial line
GND
SUPPLY 24 vdc
- +
GND
SUPPLY 24 vdc
- +
DERATING CURVES

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 primary transformers only in single phase conguration or open delta
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
Work voltage range 90…530Vac
Non-repetitive voltage 1200Vp
Rated frequency 50/60Hz auto-determination
Critical Dv/dt with output
deactivated
1000V/µsec
Held nominal voltage of on
the impulse
4KV
Breaking 5KA/480V- Warning: Maximum permissible inductance loop impedance 1000uH
Protection RC
Thermic Dissipation GFW models dissipate thermic power based on load current:
Pdissipation= 2,8W * I_load
OFP (Overcurrent Fault
Protection)
This option eliminates the need for an external extra-rapid fuse to protect the device. In case of load short-circuit, the
internal IGBT device is instantaneously switched off and the alarm status is signaled.
Rated current AC51non-
inductive or slightly inductive
loads, resistance furnaces
GFW-Xtra 40 Nominal current 40Arms @40°C in continuous service
GFW-Xtra 60 Nominal current 60Arms @40°C in continuous service
GFW-Xtra 100 Nominal current 100Arms @40°C in continuous service
Minimum load controllable: 5 % of product current rated level.
Rated current AC56A
permitted trigger modes:
ZC, BF con DT (Delay
Triggering),PA with softstart
Derating: 20% of rated current value..
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.
GENERAL DATA
Power supply 24Vdc ±10%, Class II, max 8VA Max 10VA terminal KB-ADL Isolation 1000V
Fan power supply 24Vdc ±10%, 500mA @ 25Vdc
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 - +70 °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 40°C for temperature >40°C refer at derating curves
Device type: “UL Open Type”
Attention: respect the minimum distances shown in
figure to provide adequate air circulation.
- Panel mounting and cut-out dimensions
- Installation
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., 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.
GFW Master GFW Dual-phase
GFW Three-phase
Place here
the remore
keypad
Place here
the remore
keypad
DIMENSIONS
FIXING / INSTALLATION
GFW DUAL-PHASE
(Master + 1 Expansion)
GFW THREE-PHASE
(Master + 2 Expansions)
GFW MASTER
Weight
Model with internal fuse Master Master +1 Expansion Master +2 Expansion
40A 2,2 kg 4,2 kg 6,2 kg
60A 2,2 kg 4,2 kg 6,2 kg
100A 2,2 kg 4,2 kg 6,2 kg
Lateral view
with keypad
Lateral view
without keypad