gefran GFX4-IR Owner's manual

180415F_MSW_GFX4-IR_05-2019_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: 1.4x
code: 80415F - 05/2019 - ENGLISH
GFX4-IR
4-ZONE MODULAR POWER CONTROLLER FOR IR LAMPS AND INDUCTIVE
LOADS
This document is the property of GEFRAN and may not be reproduced or transferred to third parties without authorization.
LIST OF ATTACHMENTS
This document supplements the following manuals:
- Instructions and warnings for GFXTERMO4
- Instructions and warnings for GFX4

280415F_MSW_GFX4-IR_05-2019_ENG

380415F_MSW_GFX4-IR_05-2019_ENG
TABLE OF CONTENTS AND SUMMARIES
LIST OF ATTACHMENTS ..............................................1
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 ............................................................................10
MAIN INPUT ...............................................................10
CURRENT VALUE ON LOAD ......................................14
VOLTAGE VALUE ON LOAD........................................17
LINE VOLTAGE VALUE................................................17
POWER ON LOAD ......................................................20
AUXILIARY ANALOG INPUT (LIN/TC) .........................21
DIGITAL INPUTS ..........................................................23
USING A FUNCTION ASSOCIATED WITH DIGITAL
INPUT AND VIA SERIAL...............................................24
USING A FUNCTION OF DIGITAL INPUT 1
TO ENABLE AT SOFTWARE ON .................................25
ALARMS ...........................................................................26
GENERIC ALARMS AL1, AL2, AL3 e AL4 ....................26
LBA ALARM (Loop Break Alarm) .................................31
HB ALARM (Heater Break Alarm) ................................32
SBR - ERR ALARMS
(probe in short or connection error) ..............................36
Power Fault ALARMS
(SSR SHORT, NO_VOLTAGE,e NO_CURRENT) ........37
Overheat Alarm .............................................................38
OUTPUTS .........................................................................39
ALLOCATION OF REFERENCE SIGNALS .............39
ALLOCATION OF PHYSICAL OUTPUTS ................40
SETTINGS.........................................................................43
SETTING THE SETPOINT ...........................................43
SETPOINT CONTROL..................................................44
CONTROLS ......................................................................46
PID HEAT/COOL CONTROL ........................................46
AUTOMATIC / MANUAL CONTROL.............................50
HOLD FUNCTION ........................................................50
MANUAL POWER CORRECTION ...............................50
MANUAL TUNING ........................................................51
AUTOTUNING ..............................................................51
SELFTUNING ...............................................................53
SOFTSTART.................................................................54
START MODE...............................................................54
SOFTWARE SHUTDOWN............................................55
HOT RUNNERS CONTROL .............................................56
FAULT ACTION POWER ..............................................56
POWER ALARM ...........................................................56
SOFTSTART FOR PREHEATING ................................58
HEATING OUTPUT (Fast cycle)...................................58
POWER CONTROL ..........................................................59
SSR CONTROL MODES ..............................................59
VIRTUAL INSTRUMENT CONTROL................................65
HW/SW INFORMATION....................................................66
INSTRUMENT CONFIGURATION SHEET.......................69

480415F_MSW_GFX4-IR_05-2019_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 4 temperature 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 GFX-OP operator terminal or a PC connected
in USB/232/485, with specic software (not supplied).
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
This manual is intended for technical personnel, who commission the instrument by connecting it to other units, and
for service and maintenance personnel.
It is assumed that such persons have adequate technical knowledge, especially in the elds of electronics and auto-
mation.
The instrument described in this manual may be operated only by personnel who are trained for their assigned task,
in conformity to the instructions for such task and, specically, to the safety warnings and precautions contained in such in-
structions.
Thanks to their training and experience, qualied personnel can recognize the risks inherent to the use of these
products/systems and are able to avoid possible dangers.
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.

580415F_MSW_GFX4-IR_05-2019_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.
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.

680415F_MSW_GFX4-IR_05-2019_ENG
INSTRUMENT ARCHITECTURE
The modular power controller’s exibility permits replacement of previous-version 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 4 separate instruments (recommended for retrotting projects and/or
replacement of damaged instruments);
- GFX4 mode: as a single instrument with the same functions as 4 separate instruments, but with possibility of inte-
raction among the various parameters, inputs and outputs (recommended for new projects).
New shared parameters, identied with Modbus addresses higher than 600, 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 mode lets you use a single
communication network node instead of 4 nodes as in GFX compatible mode.
When programming, keep in mind that the addres-
ses (parameters) described in this manual exist 4
times, specied by address node (ID).
Inputs ID01...
...ID04
Allocation
of outputs
Out1
Out2
Out3
Out4
Out5
Out6
Out7
Out8
Out9
Out10
GFX Compatible HARDWARE
SOFTWARE Outputs
Inputs
Inputs
Inputs
Inputs ID04
Parameters
ID03
Parameters
ID02
Parameters
ID01
Parameters
Shared parameters
Inputs
ID01
Allocation
of outputs
Out1
Out2
Out3
Out4
Out5
Out6
Out7
Out8
Out9
Out10
HARDWARE GFX4
SOFTWARE Outputs
Inputs
ID01
Allocation
of inputs
ID01
Parameters
------------------------
Custom parameters
Shared parameters
Serial line
Serial line

780415F_MSW_GFX4-IR_05-2019_ENG
SERIAL COMMUNICATION (MODBUS)
There are two Modbus addressing modes for variables and conguration parameters:
- GFX compatible
- GFX4
The modes are selected with dip-switch-7.
All the parameters of formulation are saved in internal storage EEPROM (not
own them), of which a maximum of 100.000 cycles of cancellation is guaranteed/
writing. In order to avoid the express deterioration of the same one, when the
only necessary writing is advised some. They make exception the parameters
local setpoint SP (address Modbus 138) and MANUAL_POWER (address
Modbus 252), whose memorization in EEPROM can be disabled by means of
formulation of the SP.r parameter
GFX-compatible mode (dip-switch-7 =ON)
This lets you uses supervision programs created for Geex modules.
Memory is organized in 4 groups:
- Zone 1
- Zone 2
- Zone 3
- Zone 4
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 are sequential.
Shared word parameters for the GFX4 instrument have addresses starting at 600.
Shared bit parameters have addresses high than 80.
Examples:
if the rotary switches have value 14, node 14 addresses Zone 1, node 15 Zone 2, node 16 Zone 3, node 17 Zone 4.
The process variable (PV) for Zone 1 has address Cod 0, the PV for Zone 2 has address Cod+1, 0, etc...
Parameter out.5, which denes the function of output OUT 5 on the GFX4, has address Cod 611.

880415F_MSW_GFX4-IR_05-2019_ENG
GFX4 mode (dip-switch-7=OFF)
This lets you optimize the efciency of serial communication by integrating 4 zones in the GFX4-IR. Memory is orga-
nized in 5 groups: 4 already in GFX-compatible mode, plus one group dened as custom:
- Custom (additional memory map for dynamic addresses)
- Zone 1
- Zone 2
- Zone 3
- Zone 4
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-IR 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, +8192 for Zone 4).
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... 31). This value is reset at each switch-on.
Examples:
you can access the PV variable in Zone 1 with address Cod, 0+1024 or address Cod, 0 custom variable 1 (address Cod, 200
has value 1024);
you can access the PV variable in Zone 2 with address Cod, 0+ 2048 or address Cod, 29 custom variable 30 (address Cod,
229 has value 2048);
if you want to read the 4 process variables in sequence at the rst 4 addresses, set Cod, 200 = 1024, Cod.201 = 2048, Cod,202
= 4096, Cod,203 = 8192.
CONNECTION
Each GFX4-IR has an optically isolated serial port RS485 (PORT 1) with standard Modbus protocol via connectors
S1 and S2 (type RJ10).
Connector S3 is suitable for direct connection to a Geex slave module or to a GFX-OP operator terminal. Remember that the
maximum communication speed of these devices is 19200 baud.
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” ma-
nual. Run the Autonode procedure for the Slave node parameter. For the Master, simply switch off and then back on.

980415F_MSW_GFX4-IR_05-2019_ENG
46 (od RInstrument 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
626 bav.2 R/W Select Baudrate - Serial 2 4
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.
GFX4-IRs 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).
GFX4-IRs 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.
The following procedures are indispensable for the Modbus protocol.
For the remaining protocols, see the specic Geex Probus, Geex CANopen, Geex DeviceNet and Geex Ethernet manuals.
GFX4-IR 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 GFX4-IR modules in a serial network, with node address selectable from “01” to “99” in stan-
dard mode, or create a mixed GFX4-IR/ GFX4 / Geex network in Geex compatible mode in which each GFX4-IR or GFX4
identies 4 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
- (A + 0) = Autonode Serial 1 for Geex slaves connected to GFX4-IR.
47 par R/W Select parity - Serial 1 0
0 No parity
1 Odd
2 Even
Parity table
627 par.2 R/W Select parity - Serial 2 0
Communication error
If Modbus communication between GFX4-IR and Master node goes into timeout (settable in C.E.t parameter), you can
force an output power value (C.E.P parameter of each zone) and transmit the alarm state to a relay output (rL.x parameters).
890 [.E.T R/W Timeout for communication error 0 ... 121 sec. Value 0 disables the function 0
891 [.E.
m
R/W Mode for communication error Mode table for communication error 0
0 Delivered power is not changed
1 La potenza erogata viene forzata al valore C.E.P
+16 only for C.E.M -1 in MANUAL_POWER at the restart of the
communication (only if in manual mode)
892 [.E.P R/W Output power when
communication error is active -100.0...100.0% 0,0

10 80415F_MSW_GFX4-IR_05-2019_ENG
INPUTS
MAIN INPUT
The modular power controller has 4 main inputs to control 4 temperature zones, to which you can connect temperature
sensors (thermocouples and RTD), linear sensors or custom sensors to acquire process variable (PV) values.
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.