gefran GPC Owner's manual

CONFIGURATION AND
PROGRAMMING MANUAL
Advanced Power Controller
GPC
code: 81901A “MSW_GPC-40/600A”
Software version 2.1x
81901A “MSW_GPC-40/600A”_03-2021_ENG

81901A “MSW_GPC-40/600A”_03-2021_ENG_page 1
Table of Contents ..................................................... 1
Preface ...................................................................... 5
Warnings and safety.........................................................................5
Disposal............................................................................................5
Typographical Conventions used in the manual ..............................5
Liability disclaimer............................................................................7
Copyright..........................................................................................7
1. General Description ......................................... 9
1.1. Summary................................................................................9
1.2. Field of application.................................................................9
1.3. Technicians and operators..................................................... 9
2. Commissioning...............................................11
2.1. Commissioning operations ..................................................11
2.2. Programming tool ................................................................11
2.2.1. GF_eXpress................................................................11
2.2.1.1. System requirements.........................................11
2.3. First power-on......................................................................12
3. Configuration..................................................13
3.1. Parameter legend.................................................................13
3.2. Legend for functional parameter diagrams..........................14
3.3. Modes of use .......................................................................14
3.3.1. Functional diagram of Single-node mode .................. 14
3.3.2. Functional diagram of multi-node mode.................... 15
3.4. Serial communication (Modbus) ..........................................15
3.4.1. Addressing (Cod) .......................................................15
3.4.2. Single-node mode ......................................................15
3.4.2.1. Custom Modbus memory map..........................15
3.4.3. Multi-node mode........................................................16
3.5. Time constraints of serial communication ...........................16
3.6. Connections .........................................................................17
3.6.1. Modbus network installation......................................17
3.6.2. Communication error .................................................17
3.6.3. Device identification code.......................................... 17
3.6.4. Serial port transmission speed ..................................17
3.6.5. Communication error timeout .................................... 18
3.6.6. Power delivery mode with communication error .......18
3.6.7. Output power with communication error...................18
3.7. Analog inputs .......................................................................19
3.7.1. Functional diagram of analog inputs..........................19
3.7.2. Types of analog input ................................................19
3.7.3. Analog input lower scale limit ....................................19
3.7.4. Analog input upper scale limit....................................20
3.7.5. Analog input offset.....................................................20
3.7.6. Analog input low-pass filter .......................................20
3.7.7. Analog input process value........................................21
3.8. Measuring load current ........................................................21
3.8.1. Ammeter input lower scale limit.................................23
3.8.2. Ammeter input upper scale limit ...............................23
3.8.3. Ammeter input offset ................................................. 23
3.8.4. Transformation ratio for external CT input.................24
3.8.5. Instantaneous ammeter input value...........................24
3.8.6. Filtered ammeter input value ..................................... 24
3.8.7. Peak ammeter input value .........................................24
3.8.8. Power factor...............................................................25
3.8.9. RMS load current.......................................................25
3.8.10. RMS current in three-phase load...............................25
3.8.11. Ammeter input digital filter.........................................25
3.9. Measuring load voltage........................................................26
3.9.1. RMS load voltage.......................................................27
3.9.2. Instantaneous load voltage........................................27
3.9.3. Load voltage with output activated ...........................28
TABLE OF CONTENTS
3.9.4. Voltage on three-phase load...................................... 28
3.9.5. Lower voltmeter input scale limit ...............................28
3.9.6. Upper voltmeter input scale limit ...............................28
3.9.7. Voltmeter input offset.................................................29
3.9.8. Voltmeter input digital filter ........................................29
3.10. Measuring line voltage .........................................................29
3.10.1. Lower VT voltmeter input scale limit..........................31
3.10.2. Upper VT voltmeter input scale limit..........................31
3.10.3. VT voltage transformer input offset ...........................31
3.10.4. Three-phase line unbalance threshold.......................32
3.10.5. Voltmeter input value ................................................. 32
3.10.6. Filtered voltmeter input value.....................................32
3.10.7. VOLTAGE_STATUS ................................................... 32
3.10.8. Grid frequency ........................................................... 33
3.10.9. VT voltmeter input digital filter ...................................33
3.11. Measuring the power on the load and energy consumed ...34
3.11.1. Power on load ............................................................35
3.11.2. Power on three-phase load........................................35
3.11.3. Load impedance ........................................................ 35
3.11.4. Three-phase load impedance ....................................35
3.11.5. E1 Energy consumed.................................................35
3.11.6. E2 energy consumed .................................................36
3.11.7. E1 three-phase energy consumed............................. 36
3.11.8. E2 three-phase energy consumed............................. 36
3.11.9. E1 energy consumption meter reset..........................36
3.11.10. E2 energy consumption meter reset..........................37
3.12. Digital inputs ........................................................................37
3.12.1. Definition of digital input types ..................................39
3.12.2. Digital input status .....................................................39
3.12.3. Digital input status .....................................................39
3.12.4. Digital input function ..................................................40
3.12.5. PWM input timeout .................................................... 41
3.12.6. Digital filter for PWM input .........................................41
3.12.7. PWM input value........................................................41
3.13. Generic alarms AL1 ... AL8 ..................................................42
3.13.1. Enable alarms ............................................................ 43
3.13.2. Generic alarm reference variable selection................44
3.13.3. Alarm threshold..........................................................46
3.13.4. Alarm hysteresis.........................................................48
3.13.5. Alarm type..................................................................49
3.13.6. Direct setting of a direct or reverse alarm..................51
3.13.7. Direct setting of an absolute or relative alarm ...........52
3.13.8. Direct setting of a normal or symmetrical alarm ........ 53
3.13.9. Direct setting of alarm enabling at startup.................54
3.13.10. Direct setting of alarm memory activation .................55
3.13.11. Alarm validation power ..............................................56
3.13.12. Alarm status reading ..................................................57
3.13.13. Alarm memory reset................................................... 58
3.13.14. Alarm status (ALSTATE_IRQ) .....................................58
3.14. HB (Heater Break) Alarms ....................................................59
3.14.1. Enabling alarms..........................................................63
3.14.2. HB alarm function ...................................................... 63
3.14.3. Delay time for HB alarm activation ............................64
3.14.4. Enabling calibration....................................................64
3.14.5. HB alarm threshold ....................................................64
3.14.6. HB alarm threshold percentage .................................65
3.14.7. CT reading in HB calibration......................................65
3.14.8. VT reading in HB calibration ......................................65
3.14.9. Ou.P power in calibration...........................................65
3.14.10. HB calibration with IR lamp (current) .........................66
3.14.11. HB calibration with IR lamp (voltage).........................68
3.14.12. HB alarm threshold as function of power on load .....69
3.14.13. HB (OR TA1-TA2-TA3) OR POWER FAULT alarm
status .........................................................................69
3.14.14. HB alarm status (single-phase configuration or CT
phase 1 two-phase or three-phase configuration).....70
3.14.15. HB alarm status (single-phase configuration or CT
phase 2 two-phase or three-phase configuration).....70
3.14.16. HB alarm status (single-phase configuration or CT
phase 3 three-phase configuration) ........................... 70

81901 “MSW_GPC-40/600A”_03-2021_ENG_page 2
3.14.17. ALSTATE alarm status for single-phase loads and
phase 1 of three-phase loads .................................... 71
3.14.18. ALSTATE_HB alarm status (phase 2 of two-phase/
three-phase loads and phase 3 of three-phase loads) ..
71
3.14.19. Alarm status (ALSTATE_IRQ) .....................................71
3.14.20. HB, SSR_SHORT, NO_VOLTAGE and NO_CURRENT
alarm reset .................................................................71
3.15. POWER_FAULT alarms (SSR_SHORT, NO_VOLTAGE and
NO_CURRENT) ....................................................................72
3.15.1. Enable POWER_FAULT alarms..................................72
3.15.2. SSR_SHORT update frequency.................................73
3.15.3. Time filter for NO_VOLTAGE and NO_CURRENT
alarms ........................................................................73
3.15.4. HB, SSR_SHORT, NO_VOLTAGE and NO_CURRENT
alarm reset .................................................................73
3.15.5. Status 3 (STATUS3) ...................................................73
3.15.6. SSR_SHORT alarm status (single-phase configuration
or CT phase 1 two-phase or three-phase configura-
tion) ............................................................................74
3.15.7. SSR_SHORT alarm status (single-phase configuration
or CT phase 2 two-phase or three-phase configura-
tion) ............................................................................74
3.15.8. SSR_SHORT alarm status (single-phase configuration
or CT phase 3 three-phase configuration) .................74
3.15.9. NO_VOLTAGE alarm status (single-phase configura-
tion or CT phase 1 two-phase or three-phase configu-
ration) .........................................................................75
3.15.10. NO_VOLTAGE alarm status (single-phase configura-
tion or CT phase 2 two-phase or three-phase configu-
ration) .........................................................................75
3.15.11. NO_VOLTAGE alarm status (single-phase configura-
tion or CT phase 3 three-phase configuration) ..........75
3.15.12. NO_CURRENT alarm status (single-phase configura-
tion or CT phase 1 two-phase or three-phase configu-
ration) .........................................................................76
3.15.13. NO_CURRENT alarm status (single-phase configura-
tion or CT phase 2 two-phase or three-phase configu-
ration) .........................................................................76
3.15.14. NO_CURRENT alarm status (single-phase configura-
tion or CT phase 3 three-phase configuration) ..........76
3.16. Thermal protection alarms ...................................................77
3.16.1. SSR heat sink temperature value...............................78
3.16.2. Temperature value of LINE terminals.........................78
3.16.3. Temperature value of LOAD terminals.......................78
3.16.4. Temperature value of the power board .....................78
3.16.5. Maximum temperature value of SSR heat sink..........79
3.16.6. Maximum temperature value of the power board......79
3.16.7. Status reading (STATUS4) .........................................80
3.16.8. Max1 temperature reset.............................................80
3.17. FUSE_OPEN and SHORT_CIRCUIT_CURRENT alarms......81
3.17.1. Number of automatic restarts ....................................81
3.17.2. FUSE_OPEN and SHORT_CIRCUIT_CURRENT alarm
reset ...........................................................................81
3.17.3. STATUS4 state reading .............................................81
3.18. General description of the outputs ......................................82
3.19. Allocation of reference signals to outputs............................84
3.19.1. Allocation of reference signal.....................................84
3.19.2. OUT cycle time ..........................................................86
3.19.3. Status rL.x (MASKOUT_RL) .......................................86
3.19.4. Status rL.....................................................................87
3.19.5. Allocation of physical outputs....................................88
3.19.6. Alarm status masks for custom output 9...................89
3.19.7. Alarm status masks for custom output 10.................89
3.19.8. Status reset to last activation of custom OUT9 .........90
3.19.9. Status reset to last activation of custom OUT10 .......90
3.19.10. Physical output status................................................90
3.19.11. rL.x (MASKOUT_OUT) status.....................................91
3.19.12. Alarm status stored at last activation for custom out-
put..............................................................................91
3.19.13. STATUS4 stored with custom output activation........ 92
3.19.14. ALSTATE_IRQ stored with custom output activation 92
3.19.15. VOLTAGE_STATUS stored with custom output activa-
tion .............................................................................92
3.20. Analog outputs.....................................................................93
3.20.1. Types of analog output ..............................................94
3.20.2. Analog output reference allocation ............................95
3.20.3. Lower analog output scale limit .................................96
3.20.4. Upper analog output scale limit .................................96
3.20.5. Serial line value for analog output..............................96
3.20.6. Analog output value ...................................................97
3.21. Controls - general description..............................................97
3.21.1. Reference power........................................................ 99
3.21.2. Output power value....................................................99
3.21.3. Output power value without correction ....................99
3.21.4. Power output percentage ........................................100
3.21.5. Output power offset .................................................100
3.21.6. Control output gradient............................................100
3.21.7. Minimum trigger output ...........................................100
3.22. Automatic - manual control................................................ 101
3.22.1. Manual power .......................................................... 101
3.22.2. Automatic - manual selection ..................................101
3.22.3. Status (STATUS_W) ................................................. 102
3.23. Manual power correction ................................................... 102
3.23.1. Mains voltage...........................................................102
3.23.2. Manual power correction .........................................102
3.23.3. Enabling manual power correction and storage ...... 103
3.24. Start modes........................................................................103
3.24.1. Start mode at Power-On..........................................103
3.25. Software shutdown ............................................................104
3.25.1. Software startup/shutdown ..................................... 104
3.25.2. Software shutdown modes ......................................104
3.26. Other functions...................................................................105
3.26.1. Operating hour meter............................................... 105
3.26.2. Enabling retentive memory storage .........................105
3.27. Power control modes.........................................................106
3.27.1. Enabling trigger modes............................................107
3.27.2. Maximum RMS current limit in steady state ............108
3.27.3. Minimum number of cycles of BF mode..................108
3.28. Softstart..............................................................................109
3.28.1. Maximum phase of the phase softstart ramp ..........109
3.28.2. Phase softstart ramp duration .................................109
3.28.3. Minimum non-conduction time for ramp reactivation....
110
3.28.4. Maximum peak current limit during ramp ................110
3.28.5. Phase softstart ramp restart ....................................111
3.28.6. Phase softstart ramp status.....................................111
3.28.7. Phase softstart ramp completion status..................111
3.29. Delay Triggering .................................................................112
3.29.1. Delay triggering ........................................................112
3.29.2. Delay triggering with rotation of phases 1-3-2 ........112
3.30. Automatic Firing Change function......................................113
3.30.1. Enabling Firing Change function..............................113
3.30.2. Current threshold for activating Firing Change........114
3.30.3. Current hysteresis for activating Firing Change.......114
3.30.4. Minimum power for activating Firing Change ..........114
3.30.5. Firing Change status set via serial ...........................115
3.30.6. Firing Change status set via serial ...........................115
3.31. Feedback mode .................................................................116
3.31.1. Enabling feedback mode .........................................117
3.31.2. Maximum voltage feedback correction ...................117
3.31.3. Maximum current feedback correction....................117
3.31.4. Maximum power feedback correction .....................118
3.31.5. Voltage feedback reference .....................................118
3.31.6. Current feedback reference .....................................118
3.31.7. Power feedback reference.......................................118
3.31.8. Feedback response speed ......................................119
3.31.9. Feedback reference calibration ...............................119
3.31.10. Feedback reference ................................................. 119
3.32. Heuristic power control......................................................120
3.31.11. Enabling heuristic power control .............................120
3.31.12. Maximum current for heuristic power control..........120
3.33. Heterogeneous power control ...........................................121
3.33.1. Enabling heterogeneous power control ...................121
3.33.2. Maximum current for heterogeneous power control121
3.34. Virtual instrument control ...................................................122

81901A “MSW_GPC-40/600A”_03-2021_ENG_page 3
3.34.1. Enabling instrument control via serial ......................122
3.34.2. Input control from serial ...........................................122
3.34.3. Output control from serial ........................................123
3.34.4. LED and digital input control from serial..................123
3.34.5. Virtual register address table ...................................124
3.35. HW and SW information.....................................................125
3.35.1. Software version code .............................................125
3.35.2. Hardware configuration codes.................................125
3.35.3. Hardware configuration codes 1..............................126
3.35.4. Hardware configuration codes 2/3/4 .......................126
3.35.5. Fieldbus board firmware version..............................127
3.35.6. Fieldbus board node ................................................127
3.35.7. Fieldbus board baudrate..........................................127
3.35.8. I/O data size for Fieldbus .........................................127
3.35.9. Jumper / DIP switch status......................................128
3.35.10. Enabling virtual DIP switch control ..........................128
3.35.11. Virtual DIP switch status ..........................................129
3.35.12. Manufacturer identification ...................................... 129
3.35.13. Product identification...............................................129
3.35.14. LED operation .......................................................... 129
3.35.15. RN - ER - DI1 - DI2 LED function.............................130
3.35.16. O1 - O2 - O3 LED function ......................................131
3.35.17. Status (STATUS_W) ................................................. 131
3.35.18. Alarm status reading ................................................131
3.35.19. Status (STATUS) ...................................................... 132
3.35.20. Status 1 (STATUS1) .................................................132
3.35.21. Status 2 (STATUS2) .................................................133
3.35.22. Status 3 (STATUS3) .................................................133
3.35.23. Status 4 (STATUS4) .................................................133
3.35.24. Voltage status (VOLTAGE_STATUS)........................133
3.36. Key functions .....................................................................134
4. Examples and application notes.................135
4.1. Setting parameters LS.A1/LS.A2/LS.A3 and HS.A1/HS.A2/
HS.A3 .................................................................................135
4.1.1. Full input voltage range............................................135
4.1.2. Input voltage range limited downwards...................135
4.1.3. Input voltage range limited upwards........................135
4.1.4. Formulas for calculating LS.Ax and HS.Ax..............135
4.2. Using a function associated with the digital input and via
serial...................................................................................136
4.3. Using digital input 1 to enable software startup ................ 137
4.4. Alarms ................................................................................138
4.4.1. Generic alarms AL1...AL8 ........................................138
4.4.2. HB alarm ..................................................................139
4.4.3. HB alarm threshold teach-in function ...................... 139
4.4.4. Heuristic power control............................................140
5. Using the GFW/GPC-OP keypad.................141
5.1. Description .........................................................................141
5.2. Legend ...............................................................................141
5.3. Operations..........................................................................142
5.3.1. HOME screen...........................................................142
5.3.2. Accessing the menu.................................................142
5.3.3. Browsing the menus ................................................142
5.3.4. Parameter display ....................................................142
5.3.5. Changing a numerical parameter............................. 143
5.3.6. Changing a status parameter...................................143
5.3.7. ALARM screen .........................................................143
5.3.8. Alarm reset...............................................................143
5.4. Menu structure...................................................................144
5.4.1. Main menu and 2nd level menu...............................144
5.4.2. 00 CURRENT LIMIT - 3rd level menu ......................145
5.4.3. 01 STATUS - 3rd level menu ...................................145
5.4.4. 03 COMMS - 3rd level menu ...................................146
5.4.5. 04 INPUTS - 3rd level menu ....................................146
5.4.6. 05 ALARMS - 3rd level menu...................................147
5.4.7. 06 OUTPUTS - 3rd level menu ................................148
5.4.8. 07 CONTROLS - 3rd level menu.............................. 149
5.4.9. 08 SPECIAL FUNCTIONS - 3rd level menu.............149
5.4.10. 09 POWER CONTROLS - 3rd level menu................150
5.4.11. 10 VIRTUAL - 3rd level menu...................................150
5.4.12. 11 CUSTOM MAP - 3rd level menu .........................151
5.4.13. 12 COMMANDS - 3rd level menu............................151
6. Accessories ..................................................152

81901 “MSW_GPC-40/600A”_03-2021_ENG_page 4

81901A “MSW_GPC-40/600A”_03-2021_ENG_page 5
PREFACE
Warnings and safety
Gefran always has the latest version of the Instruction Man-
ual available for free downloads and in multiple languages
at www.gefran.com. The current manual must be made
available to all people that interact with the devices this
manual describes.
Only qualified technicians, following current laws and regu-
lations should be installing this device and care be taken to
follow instructions given in this manual 2nd could be better
stated
Gefran is not liable for injury to personnel, damage to
property, other equipment, or to this device for improperly
following the instruction manuals and safety regulations.
Installation and maintenance technicians must read the
manual, following instructions written within the manual and
its annexes.
Before proceeding with this device, GPC Controller, the
technicians and operators must be sufficiently trained in
the operation, emergency, diagnostics, and maintenance
procedures for this type of device. This device can be used
in applications with risk for injury or death, damage to ma-
chines and materials, in those cases the users and installers
must combine auxiliary devices and system safegaurds to
protect against hazards.
Caution! Do not touch the terminals on the device
when it is powered.
Contact Gefran Technical Support if you suspect instrument
malfunction. Prior to contact Gefran, review the manual and
sections of the manual that pertains to the problem encoun-
tered. When contacting Gefran have the manual available
for reference.
Caution! Repairs to the Advanced Power Con-
troller must only be made by technical personnel
suitably trained and authorised by Gefran. Any
attempt to repair or modify the hardware features
of the device by unauthorised personnel will void
the warranty.
Typographical Conventions used in the manual
Disposal
Pay attention when the following symbols are found in the manual.
They indicate particularly important information
relevant to correct product operation or safety, or
provide instructions that must be strictly followed.
This highlights a risk condition for the installation
technician or user due to hazardous voltage levels.
This calls the reader’s attention to a specific point.
The instrument must be segregated from other
waste at the end of its useful life.
The user must take the equipment at the end of
its useful life to an appropriate sorting centre for
electrotechnical and electronic waste, or a similar
facility, in accordance with the regulations in force
in the country of installation, in order to dispose of
the components which are potentially harmful to
the environment.
This indicates a suggestion that could be helpful
for better use of the device.
This indicates a reference to other technical docu-
ments that may be downloaded from www.gefran.
com.
WWW
This helps prevent negative effects on the envi-
ronment and health and facilitates recycling of the
materials from which the instrument is made.

81901 “MSW_GPC-40/600A”_03-2021_ENG_page 6

81901A “MSW_GPC-40/600A”_03-2021_ENG_page 7
Liability disclaimer
Copyright
Although all the information in this document has been
carefully checked, Gefran S.p.A. cannot be held liable for
the possible presence of errors, or for damage to persons
or property due to improper use of this manual.
Gefran S.p.A. also reserves the right to make changes to
the content and form of this document and to the features
of the devices it describes at any time without prior notice.
The technical and performance data given in this manual
are to be considered as a guide for the user to determine
the suitability for a certain use and are not a guarantee.
They may be the result of Gefran S.p.A. test conditions
and the user must compare them to his/her real application
requirements.
Gefran S.p.A. cannot be held in any way liable for damage
to persons or property resulting from tampering or use that
is incorrect, improper or otherwise incompliant with the
features of the controller and the instructions contained in
this manual.
Gefran S.p.A. shall not be liable for installations upstream or
downstream from the instrument.
This document and its annexes may be freely reproduced,
provided that the contents are not modified in any way
and each copy includes this warning and the statement of
Gefran S.p.A. ownership.
Gefran and GF_eXpress are trademarks of Gefran S.p.A.
The document may mention or reproduce trademarks and
logos of third parties. Gefran S.p.A. acknowledges the
rights over these trademarks or logos of their respective
owners.

81901 “MSW_GPC-40/600A”_03-2021_ENG_page 8

81901A “MSW_GPC-40/600A”_03-2021_ENG_page 9
1. GENERAL DESCRIPTION
1.1. Summary
The GPC Advanced Power Controller is a self-contained
unit for independent control of up to 3 phases. It features
a high level of operational flexibility achieved through the
extensive configurability and programmability of its param-
eters.
The Advanced Power Controller is the ideal solution for
applications in heat treatment ovens, autoclaves, glass
furnaces and dryers.
Due to its high level of programmability, the controller can
also be used in other applications, provided that they are
compatible with the technical specifications of the instru-
ment.
The instrument can be configured and programmed using
a keypad (GFW/GPC-OP) or a PC installed with the special
GF_eXpress application
software and connected to the instrument via a Gefran
RS485 to USB cable (F055002).
1.2. Field of application
1.3. Technicians and operators
As the Advanced Power Controller can be used in a multi-
tude of installations and environments, adequate technical
training is required to make full use of the instrument’s
potential.
In any case, the instrument must always be used within the
limits specified in the technical specifications in the accom-
panying documentation.
Regardless of any other consideration, it is always strictly
prohibited to:
• use the instrument or parts of it (including the software)
for purposes other than those specified in the accom-
panying technical documentation;
The Advanced Power Controller must only be used by per-
sonnel qualified for the assigned task, in compliance with
the instructions for that task, especially the safety warnings
and precautions they contain.
Qualified personnel, due to their training and experience,
are able to recognise the risks involved in using the instru-
ment and avoid potential hazards.
• change the working parameters not accessible to the
operator, or decrypt or transfer the software or parts of
it;
• use the instrument in particularly flammable environ-
ments;
• repair or modify the instrument using non-original spare
parts;
• use the instrument or parts of it without having read
and correctly interpreted the contents of the accompa-
nying technical documentation;
• dispose of or discard the instrument in common land-
fills.
In addition, it is assumed that the technicians who commis-
sion the instrument and connect it to other units, and those
who carry out maintenance, have sufficient technical knowl-
edge, particularly in the field of electronics and automation,
to fully understand the information provided in this manual.

81901 “MSW_GPC-40/600A”_03-2021_ENG_page 10

81901A “MSW_GPC-40/600A”_03-2021_ENG_page 11
2. COMMISSIONING
2.1. Commissioning operations
2.2. Programming tool
2.2.1. GF_eXpress
GF_eXpress is the configuration tool for components, auto-
mation, drives and sensors in the Gefran catalog.
GF_eXpress tool is easy and intuitive thanks to a graphical
interface, with devices divided according to product type
and function. The choice of the product to be configured is
made through a contextual menu with visual selection using
real product images.
This management makes it possible to have a single device
library for all Gefran products.
The software is available free of charge and can be down-
loaded from www.gefran.com, where it is always updated
to the latest version available.
Applications
• Create a resource library of all Gefran devices on the
plant floor (instrumentation, drives, sensors, power
controllers). of Gefran devices (instrumentation, drives,
sensors).
• Tuning of adjustment parameters with on-line test and
Trend.
• Parameter archive management for multiple configura-
tions.
Features
• Guided product selection.
• Simplified setting.
• Multilingual.
• Print parameters.
• Creation and saving of recipes.
• Network autoscan.
2.2.1.1. System requirements
Minimum Recommended
Operating
system
Windows XP SP2,
Windows Vista or
Windows 7 (32-bit)
Windows 10 (64
bit)
Processor Intel Pentium
1 GHz
Intel Core i7 2.9
Ghz or higher
RAM 2 GB 4 GB or more
Free hard
disk space
2 GB 4 GB or more
Graphic res-
olution
XGA
(1024 x 768 pixels)
SXGA (1280 x 1024
pixels) or higher
Browser Microsoft Internet
Explorer 8.0
Microsoft Edge or
higher
Ethernet Port 1 RJ45 1 RJ45
DVD player Yes Yes
USB port 1 USB 2.0 1 USB 2.0
The simplest and safest way to commission GPC Advanced
Power Controllers, after connecting the 24 Vdc power sup-
ply and a PC to the CPU, is to use the GF_eXpress software
and its “SMART CONFIGURATION” function.
Through the “SMART CONFIGURATION” wizard menu, a
safe working recipe can be created to test the controller
and its load in just a few minutes, by answering some sim-
ple questions about the application.
Connection from PC to GPC, use cable Gefran F055002
which is a USB to RS485 type cable.

81901 “MSW_GPC-40/600A”_03-2021_ENG_page 12
2.3. First power-on
For commissioning of the Advanced Power Controller, the
following steps and checks must be carried out:
1. Connect the line and load cables in accordance with
the wiring diagram and leave the power line fuses
open.
2. Connect the analog and/or serial/fieldbus communica-
tion signals.
3. Power the GPC-M module via a 24 Vdc power supply.
4. Once the GPC-M is switched on, the LEDs start turning
on and off to indicate CPU initialisation. The following
sequence is seen:
a) All 8 LEDs on steadily at the same time for approx.
2 seconds.
b) All 8 LEDs flashing simultaneously 3 times for
approx. 2 seconds.
c) The LEDs light up in sequence from number 1 to
number 8.
5. Finally, the “RUN” (green) and “ER” (red) LEDs remain
flashing. The “ER” LED will turn off when Digital Input 4
is subsequently connected.
6. Proceed with programming:
a) Connect the PC to the GPC-M.
b) Open the GF_eXpress software and select “IN-
STRUMENTS” and then, in the “Solid State Relay”
drop-down menu, select GPC 40-600A.
c) After setting the configuration parameters, select
the “SMART CONFIGURATOR” menu.
d) Complete the indicated steps providing the re-
quired information.
e) Save the final parameter recipe and send it to the
controller.
f) Select “WIZARD”.
g) Select “M” and check the following parameters
and their values in the data sheet: OFF/ON = OFF;
MAN/AUTO=MAN, Man.P=0.0. Change the
parameter if necessary.
7. Close the power line fuses.
8. Connect the ENABLE/INTERLOCK signal to Digital In-
put 4. The “ER” LED (red) goes off. If this 24 Vdc signal
is not present, the controller is not enabled to supply
output power to the load and the “ER” LED remains lit.
9. Change the value of the following parameters with
GF_eXpress: OFF/ON = ON; Man.P= 10.0. With this
action the output is activated at 10% power.
10. If the “ER” (red) LED flashes, the power will not be
delivered. Check for the following possible causes:
• Fuses not closed.
• No line voltage.
11. Check:
• for the GPC 400...600A models, the connection of
the Ref.V_LINE and Ref.V_Load signals (terminals
3/L1 and 4/L2 on connector J6 and, depending on
the options, also check terminals 6/T2 and 5/T1 on
connector J7);
• for the GPC 40...300A models, the connection of
the Ref.V_LINE and Ref.V_Load signals (terminals
3/L2 and 4/T2 and, depending on the options, also
terminals 5/T3 of connector J10).
12. Test the system by increasing the percentage of power
to the load in small steps (Man.Pparameter) and check-
ing the correct behaviour of the controller using the
monitor functions in GF_eXpress.

81901A “MSW_GPC-40/600A”_03-2021_ENG_page 13
3. CONFIGURATION
Configuration and programming of the Advanced Power
Controller can be performed with a keypad (GFW/GPC-OP)
or preferably with a PC installed with the special GF_eX-
press application software and connected to the instrument
via a USB cable (F055002), which can be ordered from
Gefran.
For more information on programming with the keypad, see
chapter “5. Using the GFW/GPC-OP keypad”.
For more information on programming with a PC, see the
GF_eXpress documentation available at www.gefran.com.
Caution! Advanced knowledge of the problems
and techniques associated with control is required
to correctly set the parameters needed to con-
figure the Advanced Power Controller so that it
meets the application requirements.
Caution! Before commissioning the controller, the
user must ensure that the parameters are set cor-
rectly to avoid damages to persons or property.
If you are unsure of your skills or not fully aware of the
potential consequences of incorrect parameter settings, we
advise you not to proceed with the configuration.
If in doubt, or if you would like some clarification, please
visit www.gefran.com or contact the Gefran Customer Care
service.
1. Parameter address in Single-node mode.
2. Parameter address in Multi-node mode.
3. Parameter format, which can be:
• bit,
• 16 bit,
• 32 bit.
4. Menu address with the GFW/GPC-OP keypad.
5. Acronym by which the parameter is identified.
6. Indicates whether the parameter is global or only af-
fects a particular module.
7. Complete path of the GF_eXpress menu.
8. Parameter attribute:
• R = the parameter is read-only,
• R/W = the parameter can be read and written.
9. Indicates whether the parameter value remains stored
even after the controller is switched off.
10. Indicates the type of parameter.
With 16-bit parameter it can be:
• Unsigned Short,
• Short,
• Float (the position of the decimal point is indicated
in brackets).
With 32-bit parameter (16-bit LSW at parameter ad-
dress + 16-bit MSW at parameter address + 1) it can
be:
• Unsigned Int,
• Float32 (the position of the decimal point is shown
in brackets).
11. Unit of measurement of the value managed by the pa-
rameter. The unit of measurement can be unique or
depend on other configuration choices, such as the
temperature unit, which can be set either to Centigrade
or Fahrenheit.
Not all parameters have units of measurement.
12. Factory parameter value.
13. Value that the parameter can take. The value can be of
two types: discrete or belonging to a range of values,
typically numerical. With a discrete value, all possible
values are listed. With value ranges, the minimum
and maximum values that the parameter can take are
shown.
14. Full description of the parameter.
1 2 3 4 5 6
13 14
7 8 9 10 11 12
3.1. Parameter legend
NOTE: 16 bit data is integer type. Decimal representation is virtual only and must be managed by the display device. A
maximum of 16 continuous 16 bit register may be read at one time. See Modbus Address Manual for full details.

81901 “MSW_GPC-40/600A”_03-2021_ENG_page 14
The GPC Advanced Power Controller can be used and
addressed in two different modes:
• Single-node, in which GPC behaves as an individual
single-phase, two-phase or three-phase controller.
• Multi-node, in which GPC behaves as if it were several
separate single-phase controllers (max 3).
The difference consists in in the way it is used on the appli-
cation and the way the parameters are addressed.
New common parameters are available in both modes,
allowing more advanced functions.
Single-node mode, in addition to having a set of customis-
able custom parameters for dynamic addressing, allows
only one node to be used in the communication network,
instead of the 3 nodes required by Multi-node mode.
3.2. Legend for functional parameter diagrams
3.3. Modes of use
Physical input
Controller
Internal vari-
able
Parameter
processing
Physical output
Processing with
parameters
Parameter
or read-only
variable
3.3.1. Functional diagram of Single-node mode
Note: Out 4 does not exist
ID01
Parameters
Common parameters
Custom parameters
OUT5
OUT1
Inputs
OUT6
OUT2
OUT7
OUT3
OUT9
OUT8
OUT10
SOFTWARE OUTPUTSINPUTS
SERIAL LINE
ID01
Allocation of
outputs
ID01
Allocation of
inputs

81901A “MSW_GPC-40/600A”_03-2021_ENG_page 15
3.4. Serial communication (Modbus)
3.4.1. Addressing (Cod)
GPC devices are identified uniquely identified through the
node address (Cod, i.e., device identification code) set with
the two hexadecimal rotary switches (tens + units). The
address is read-only.
Up to 99 GPC devices can be installed in a serial network,
with a selection of standard node addresses from ‘01’ to
‘99’ (hexadecimal settings A, B, C, D, E are reserved).
The selection of Single-node or Multi-node operating mode
is made via DIP switch 7.
3.4.2. Single-node mode
The default mode selected is Single-node. This mode is
activated by setting DIP switch 7 = OFF and it allows the
serial communication efficiency to be optimised by integrat-
ing several modules (a maximum of 3) with the Advanced
Power Controller.
The memory is organised in groups: the modules (max
3) are the same as in Multi-node mode, plus the Custom
group. Thus, you have:
• GPC-M for the controller’s M module variables.
• GPC-E1 for the controller’s E1 module variables.
• GPC-E2 for the controller’s E2 module variables.
• Custom, which collects up to 120 variables and param-
eters, each one word long, the meaning of which can
be changed.
The set value (Cod) on the rotary switches is unique.
The address of the individual modules is the same as the
Multi-node address with a fixed offset (+1024 for GPC-M,
+2048 for GPC-E1 and +4096 for GPC-E2).
For example, to access the variable Ou.P, which contains
the value of the control output, you use:
• the address Cod, 1026 (= Cod, 2+1024) for GPC-M,
• the address Cod, 2050 (= Cod, 2+2048) for GPC-E1,
• the address Cod, 4098 (= Cod, 2+4096) for GPC-E2.
“2” is the address of the variable Ou.P in Multi-node mode.
3.4.2.1. Custom Modbus memory map
The addresses 0 to 119 correspond to the words of the
Custom group; variables and parameters are defined by
default.
The Custom Modbus map, accessible via the Main Menu →
Custom Map, allows a word memory area of 32 contiguous
elements to be defined in order to make use of the Modbus
multi-word read and write commands and thus speed up
data exchange with a Modbus Master device.
The parameters defining the 120 internal variables, to be
read or written contiguously, are available in GF_eXpress
Custom Map in addresses 200 to 319. Addresses 0 to 119
contain the value of these parameters.
Addresses 200...319, the values of the Custom
variables and parameters, are protected against
overwriting.
To enable writing, the value 99 must be written to
addresses 600 and 601. The value 99 is reset at
each startup.
Example of memory map use
You want to access the Ou.P (power output) variables from
GPC-M, GPC-E1 and GPC-E2.
The 3 required Modbus addresses are 1026 for GPC-M,
2050 for GPC-E1 and 4098 for GPC-E2. Given the Modbus
addresses of the three parameters, three separate requests
would be necessary if the Custom map was not used.
3.3.2. Functional diagram of multi-node mode
ID01
Parameters
ID02
Parameters *
ID03
Parameters **
Common parameters
Inputs
OUT5
OUT1
Inputs
OUT6
OUT2
Inputs OUT7
OUT3
OUT9
OUT8
OUT10
SOFTWARE OUTPUTSINPUTS
SERIAL LINE
ID01
...
ID03
Allocation of
outputs
*) if GPC-E1 module is present
**) if GPC-E2 module is present
Note : Out 4 does not exist

81901 “MSW_GPC-40/600A”_03-2021_ENG_page 16
To read these quantities in a single request, thereby reducing
the update times, simply do the following in GF_eXpress:
• in the CustomVar1 object (address 200) enter the value
1026, i.e., the Modbus address of the first parameter to
be accessed;
• in the CustomVar2 object (address 201), the value
2050, i.e., the Modbus address of the second parame-
ter to be accessed;
• in the CustomVar3 object (address 202), the value
4098, i.e., the Modbus address of the third parameter
to be accessed.
At this point, through the Modbus read command of three
consecutive addresses starting from 0, the three powers
supplied can be accessed by means of a single operation.
3.4.3. Multi-node mode
This mode is activated by setting DIP switch 7 = ON.
The memory is organised in groups:
• GPC-M for the controller’s M module variables.
• GPC-E1 for the controller’s E1 module variables.
• GPC-E2 for the controller’s E2 module variables.
The value set (Cod) on the rotary switches corresponds to
that of GPC-M; that of the other modules, if present, is in
sequence (Cod+1 for GPC-E1, Cod+2 for GPC-E2).
Examples
The rotary switches show the value 14. Therefore, node
(Cod) 14 addresses GPC-M, node 15 addresses GPC-E1
and node 16 addresses GPC-E2.
Using this setting, for example, the variable Ou.P in GPC-M
will have the address 14, 2 (=Cod, 2), the variable Ou.P in
GPC-E1 will have the address 15, 2 (=Cod+1, 2) and the
variable Ou.P in GPC-E2 will have the address 16, 2 (=
Cod+2, 2).
3.5. Time constraints of serial communication
In order to permit correct serial data exchange with the
device, the following time constraints must be respected:
• Reading register/word parameters
Reading nconsecutive parameters, with nvarying from
1 to 16, requires a time of:
–40 ms with retentive memory enabled (default),
–35 ms with retentive memory disabled.
The retentive memory setting is obtained through the
parameter EEP.E (see paragraph “3.26.2. Enabling
retentive memory storage”).
Thus, the next Modbus command to the same node,
whether read or write, must be sent after this delay
time has expired.
• Writing parameters to register/word
The writing of nconsecutive parameters, with nvarying
from 1 to 16 and a complete set of updated values (16
in total) with regard to those currently present on the
device, requires a time of:
–40 ms + (nx 10 ms *) with retentive memory ena-
bled (default),
–35 ms with retentive memory disabled
The retentive memory setting is obtained through the
parameter EEP.E (see paragraph “3.26.2. Enabling
retentive memory storage”).
Thus, the next Modbus command to the same node,
whether read or write, must be sent after this delay
time has expired.
The times given refer to cases with a serial baudrate of
19200. Lower baudrates increase transmission times and
thus waiting times.
Notes
*) If the STATUS_W parameters (Modbus address 305) are
included in the write request, and their value is different
from the one currently present in the slave, the time
needed to write each one will be 30ms instead of 10ms
Note: The Custom map function is not available in Multi-node mode

81901A “MSW_GPC-40/600A”_03-2021_ENG_page 17
3.6. Connections
In a network, a “Master” device can be identified, which
communicates through commands, and “Slave” devices,
which interpret and implement the commands. The GPC
devices are the Slaves and the Master is the supervisor
terminal or a PLC.
Each GPC device is equipped with an opto-isolated RS485
serial port (PORT 1 or serial 1) which uses the standard
Modbus protocol. The connectors used are J8 and J9
(RJ10 type). An additional optional serial interface (PORT 2
or serial 2) can also be inserted into the device to connect
to the required fieldbus. Interfaces are available for con-
nection to Modbus, Profibus DP, CANopen and Ethernet
(Modbus TCP, EtherCAT and EthernetIP).
A parameter can be read or written from both PORT 1 and
PORT 2 and both communication ports respond to the
same Cod address.
3.6.1. Modbus network installation
The procedure described below is for the Modbus protocol.
For the remaining protocols, please refer to the specific
fieldbus manuals available at www.gefran.com.
GPC devices leave the factory with the following settings:
• Cod = 0 (rotary switches set 0 + 0)
PORT 1
(Serial 1)
PORT 2
(Serial 2)
Speed (bit/s) 19200 19200
Parity No parity No parity
In summary, the valid settings on the rotary switches (tens
+ units) are:
• (0 + 0) = Autobaud Serial 1
• (B + 0) = Autobaud Serial 2
The communication parameters for PORT 1 are bAu, which
allows the speed to be set in bits/s, and Par, which allows
the parity to be set.The corresponding parameters for
PORT 2 are bAu.2 and PAr2.
Changing the parameters bAu and PAr may invali-
date the communication.
3.6.2. Communication error
If a communication error occurs between the GPC device
and the Master device, it is possible to force an output
power value (C.E.P parameter of each module) and transmit
the alarm status to a relay output (rL.x parameters).
If the communication error is caused by the timeout, the
timeout time can be changed in the C.E.t parameter.
3.6.3. Device identification code
Address
Format GPC-OP
menu Acronym
Global / M/E1/E2
GF_eXpress menu
Attribute Retentive Type Unit of mea- surement Default
Single-
node
Multi-
node
Description
1070 46 16 bit 02.09 Cod Global MainMenu →Global →Info →Cod RUnsigned
Short 10
The parameter shows the identification code of the GPC device, which is set with the hexadecimal rotary switches.
min...max: 1...99
3.6.4. Serial port transmission speed
Address
Format GPC-OP
menu Acronym
Global / M/E1/E2
GF_eXpress menu
Attribute Retentive Type Unit of mea- surement Default
Single-
node
Multi-
node
Description
1069 45 16 bit 03.01.01 bAu Global MainMenu →Global →Info →bAu R/W ■Unsigned
Short 4
1650 626 16 bit 03.01.03 bAu.2 Global MainMenu →Global →Info →bAu.2 R/W ■Unsigned
Short 4
The parameter sets the transmission speed of the serial port.
Options: 0= Speed 1200 bit/s
1= Speed 2400 bit/s
2= Speed 4800 bit/s
3= Speed 9600 bit/s
4= Speed 19200 bit/s
5= Speed 38400 bit/s
6= Speed 57600 bit/s
7= Speed 115200 bit/s

81901 “MSW_GPC-40/600A”_03-2021_ENG_page 18
3.6.5. Communication error timeout
Address
Format GPC-OP
menu Acronym
Global / M/E1/E2
GF_eXpress menu
Attribute Retentive Type Unit of mea- surement Default
Single-
node
Multi-
node
Description
1914 890 16 bit 02.09 C.E.t Global MainMenu →Global →Info →C.E.t R/W ■Unsigned
Short sec. 0
The parameter sets the timeout time before a communication error is generated.
Setting the parameter to “0” disables the communication error.
min...max: 0...121
3.6.6. Power delivery mode with communication error
Address
Format GPC-OP
menu Acronym
Global / M/E1/E2
GF_eXpress menu
Attribute Retentive Type Unit of mea- surement Default
Single-
node
Multi-
node
Description
1915
891 16 bit
03.02.01
C.E.m
MMainMenu →M →Controls → C.E.m_1
R/W ■Unsigned
Short 02939 03.03.01 E1 MainMenu →E1 →Controls → C.E.m_2
4987 03.04.01 E2 MainMenu →E2 →Controls → C.E.m_3
The parameter defines what happens to the power delivered from the output of the GPC device when a communication error occurs.
Options: 0= The power delivered is not changed
1= The power delivered is forced to the value determined by the parameter C.E.P
3.6.7. Output power with communication error
Address
Format GPC-OP
menu Acronym
Global / M/E1/E2
GF_eXpress menu
Attribute Retentive Type Unit of mea- surement Default
Single-
node
Multi-
node
Description
1916
892 16 bit
03.02.02
C.E.P
MMainMenu →M →Controls → C.E.P_1
R/W ■Float
(####.#) % 0.02940 03.03.02 E1 MainMenu →E1 →Controls → C.E.P_2
4988 03.04.02 E2 MainMenu →E2 →Controls → C.E.P_3
When a communication error occurs, if the parameter C.E.m has been set to “1”, the parameter sets the power delivered by the output of
the GPC device as a percentage value of the maximum power that can be delivered by the output.
min...max: 0.0...100.0