gefran GSLM User manual

User Manual
code: 80582_11-2020_ENG
GSLM
Smart Load Manager

280582_User Manual_GSLM_11-2020_ENG

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80582_User Manual_GSLM_11-2020_ENG
SUMMARIES AND TABLES OF CONTENTS
SUMMARIES AND TABLES OF CONTENTS������������������� 3
GSLM scope���������������������������������������������������������������������� 4
Functions overview���������������������������������������������������������� 6
General information���������������������������������������������������������� 6
Burst Firing mode ������������������������������������������������������������ 8
Function overview ������������������������������������������������������������ 8
GSLM graphic interface ��������������������������������������������������� 9
Initial page������������������������������������������������������������������������ 9
Page overview 1��������������������������������������������������������������� 9
Page Alarms active ���������������������������������������������������������� 9
Page overview 2��������������������������������������������������������������� 9
Page maintenance ��������������������������������������������������������� 10
Page conguration 1 ������������������������������������������������������ 10
Page conguration 2 ������������������������������������������������������ 10
System pages ����������������������������������������������������������������� 11
Alarms active page��������������������������������������������������������� 11
History alarms page ������������������������������������������������������� 11
History data page ����������������������������������������������������������� 11
User login page �������������������������������������������������������������� 11
User manager page ������������������������������������������������������� 12
Date hour page �������������������������������������������������������������� 12
Language page �������������������������������������������������������������� 12
Net conguration page ��������������������������������������������������� 13
Power graphs page �������������������������������������������������������� 13
Power efciency factor ��������������������������������������������������� 13
Data log conguration and USB exporting page ������������ 14
Hardware ������������������������������������������������������������������������� 15
Dimension ���������������������������������������������������������������������� 15
Assembly and Installation ���������������������������������������������� 16
Main power supply ��������������������������������������������������������� 18
Technical data ���������������������������������������������������������������� 19
Connections ������������������������������������������������������������������� 20
Architectures ������������������������������������������������������������������ 22
Modbus TCP address map��������������������������������������������� 23
Modbus TCP Slave address map����������������������������������� 24
Maintenance and Diagnostics ���������������������������������������� 24
System conguration quick start���������������������������������� 25
Order code ���������������������������������������������������������������������� 26

480582_User Manual_GSLM_11-2020_ENG
The goal of the GSLM is to optimize the management of
resistive electric loads� A typical issue, in plants, that use
electric heating systems, is to absorb instantaneous
electrical powers that are considerably higher than the
average required ones� A not managed distribution of
demand leads to an increase in the cost of electricity supply�
The increase is not due to actual greater consumption of
energy, but by the absorption peaks reached� Generally, the
tariffs for electricity supplies, vary according to the maximum
absorption achieved during a given period� The reached
peak determines the energy price *�
To measure the imbalance of absorption over time, we use
the Power Efciency Factor.
PEF=(Pmax -( Pimax - Pimin))/Pmax
Where Pmax is the total of the installed powers. Pimax and
Pimin are respectively the maximum and minimum powers
reached by adding the instantaneous powers of each load�
*NOTE: How and much how the price is increased will
depend on the contract. Automatic contract-size changes
can be implemented by the distributor, with a relative
increase in maintenance costs required� In addition, could
be applied xed costs for each kW exceeded above the
contractual threshold�
The peaks can occur mainly for two reasons: rst is the
high absorption in the initial stages of heating, the second
is the lack of temporal organization of the ring. With the
GSLM connected to Gefran’s GFW/GPC and GPC power
controllers, these situations can be avoided� The supervision
of the powers required of each controller is processed by the
GSLM to plan the best ring strategy. The GSLM consists of
two main features:
-Load Shedding: makes sure that the required power does
not exceed a certain threshold. If this happens, the delivery
will be postponed ensuring a cut in peak absorption�
-Load Sharing: distributes the ON and OFF cycles of the
individual controllers over time as evenly as possible, trying
to achieve maximum absorption efciency (PEF=1).
Let’s take the example of a 500kW installed power heat
treatment plant� The system will typically absorb 100%
of power (500kW) only in the start-up phase, while
the maintenance phase will have a very low average
consumption, let’s assume 50% (250kW). This is the typical
situation, where the initial peak is used to achieve plant
stability in the shortest possible time� The other situation in
which power peaks can occur is the maintenance phase�
However, it is necessary to analyze the load control strategy
in more detail, to understand how peaks can be generated in
a phase in which only 50% of power is required. Let’s assume
that the plant in question is managed by 10 power controllers
of 50 kW each, which work in full waves, alternating the ON
and OFF cycles� The 10 controllers will go to 50% of their
nominal load� Therefore, 50% of the periods to 50 kW and
the remaining 50% to 0 kW� This means that, if the correct
ring synchronization is not provided, the system could
absorb peaks of 500 kW even if the average consumption
is 250 kW�
The Power Efciency Factor in this case, without the
intervention of the GSLM, is 0. Because Pmax=10x50kW=
500kW, Pimax and Pimin worth respectively 500kW and
0kW� The situation described above is represented in the
following graph�
Trend of the instantaneous power during the control at 50% of the
total power (PEF=0)
By letting the power controllers work independently, even
better conditions could be achieved, but these are not
always guaranteed. See the following graph for an example.
Trend of the instantaneous power during the control at 50% of the
total power without GSLM action (PEF=0.6)
In this simple example it is clear that to improve the results
it would be enough to combine the ON cycles of the rst
5 controllers with the OFF cycles of the second 5 and
vice versa. At this point, the Pimax would be 250kW, like
the Pimin, and therefore the PEF = 1� The result of this
management is the one shown in the following graph�
Trend of the instantaneous power during the control at 50% of the
total power with the action of the GSLM (PEF = 1)
GSLM SCOPE

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80582_User Manual_GSLM_11-2020_ENG
Architecture diagram 1
Architecture diagram 2

680582_User Manual_GSLM_11-2020_ENG
General information
As seen above the functionalities of the GSLM can be
divided in two concepts that can work together. The rst
concept, named Power distribution (Load Sharing), takes
care of the ring distribution to all the Power Controllers, in
a way that minimizes the instantaneous current peaks and
is able to distribute the energy consumption along all the
control period time�
The effect is a considerable reduction of current variations
and peaks and a better Power Efciency Factor�
FUNCTIONS OVERVIEW
Nr. 5 Zones (I = 10A) – (P% = 20%)
Power distribution: DISABLE / Power limit: NONE
Nr. 5 Zones (I = 10A) – (P% = 20%)
Power distribution: ENABLE / Power limit: NONE

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80582_User Manual_GSLM_11-2020_ENG
The second part, Power Limit (Load Shedding), takes
care of the eventual total power limit that can be set for
the plant� This limit will never be exceeded, the GSLM
Unit will insure a reduction of the power on all the zones,
meanwhile it continues to provide the load sharing control
as well�
The result of these two algorithms working together will be
a stable power consumption not exceeding the congured
power limit�
Nr. 5 Zones (I = 10A) – (P% = 20% - 20% - 40% - 60% - 80%)
Power distribution: DISABLE / Power limit: NONE
Nr. 5 Zones (I = 10A) – (P% = 20% - 20% - 40% - 60% - 80%)
Power distribution: ENABLE / Power limit: ENABLE

880582_User Manual_GSLM_11-2020_ENG
The following features are available:
• Limiting the maximum instantaneous consumption
peaks (Load sharing)
• Limiting the maximum power consumption of all the
zones (Load shedding)
• Control type: Burst Firing algorithm�
For each zone, the nominal power and the maximum
output power required by the heating system must be
congured.
If the total power required by the control loop PIDs is
greater than the maximum output power:
• The power sent to the individual Power Controllers
is reduced, compared to the value calculated by the
PID, in proportion to the reduction calculated;
• The total instantaneous power output is limited to the
maximum set value.
If instead the overall power required by the control loop
PIDs is less than the maximum deliverable power:
• The individual Power Controller will receive the
power calculated by the PID;
The control of the heating outputs is performed with periods
that are multiples of the power line period� Therefore, with
a 50 Hz power line the control will use multiple periods of 20
ms, while multiple periods of 16 ms will be used with 60 Hz�
Burst Firing mode
The GSLM works in Burst ring mode: the output, the
output is controlled to ON or OFF cycles according to the
power calculated by the PID�
Burst Firing mode improves the power output control in the
following ways:
• An accurate burst switch between ON and OFF
ensures a uniform distribution of energy over time�
Example: if the PID calculates a power of 50.0% one
wave will be applied to the load (ON ), one wave will
be stopped (OFF).
• The output is exactly that required by the PID (one
thousand of accuracy). Example, if the PID calculates
a power of 51�2%, the control cycle will be 512
burst ON and 488 burst OFF cycles, following with
continuous alternation of burst ON and OFF cycles�
• The power output control is adjusted immediately to
the values calculated from the PID
Further, with the Burst Firing control, the total energy
delivered to the outputs of heating is distributed effectively
over time between different areas�
Function overview
The general operation requires that the single GFW/GPC
connected in the network receive the power command (P%)
from an analog signal wired in the terminal board or from
remote device (DCS/PLC) via Modbus TCP network or
manually directly from the GSLM graphic interface�
This value is read by the GSLM via Modbus TCP and on
the basis of the set conguration (max total power) it sends
via Modbus TCP, to the individual GFW/GPC, the digital On/
Off power on command� It is required that each Power
Controller have the Ethernet Modbus TCP eldbus
Option�
The ring mode of the GFW/GPC, to work properly with
GSLM, is “Burst Firing”
• For single phase loads controlled by phase-phase or
by phase-neutral connection
• For Dual phase with closed delta or star without
neutral connection
• For three phases with star (with or without neutral) or
delta (closed or open) connection
Main features overview:
• GSLM can manage 16, 32, or 64 GFW/GPC units in
a Modbus TCP network with three models:
- GSLM-16
- GSLM-32
- GSLM-64
• Total limitation of power peak consumption
• Optimized distribution of individual loads (load
sharing)
• Three different power control modes:
-Wired analog signal
- Power reference from DCS/PLC via
Modbus TCP network
-Manual from GSLM interface
• ON/OFF control (enable/disable power) of each
GSLM Power controller
• Modbus TCP slave
• Remote service (option)
• Remote interface (VNC)
• DIN rail mounting
• Graphical conguration interface
• Diagnostic pages
• Alarm management (real/historical)
• Three levels of conguration access
There are 3 levels of access to the GSLM conguration:
- Operator Level
- Maintenance Level
- Admin Level
Access to the conguration is via Ethernet network both
locally and remotely� The page and VNC remote service is
protected by a customer-modiable password.
All data managed by GSLM are published as Slave Modbus TCP
and available for connection to a Master Modbus TCP device�

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80582_User Manual_GSLM_11-2020_ENG
GSLM GRAPHIC INTERFACE
A series of graphic interfaces are provided for the
conguration and diagnostics of the GSLM system.
The graphic pages are available with a VNC interface�
Access to VNC pages is password-protected.
The ETH2 IP address, available for the VNC and Automation
network, is 200�19�10�100 � Default password for VNC:
adminadmin �
The ETH1 IP address, available for the Factory network and
also for the VNC, is 192�168�1�100 �
The resolution of the graphic pages is based on a 15”
screen size�
All pages have a common layout:
• Current Date/Time Display
• Active user and direct access to Log In page
• Alarm status and direct active alarms page access
• Active control mode (Analog / DCS-PLC / Manual)
• Page name
• A series of buttons that allow access to the various
conguration or display interfaces. Access to the
pages is limited according to the active user level�
The following main pages are available:
• Start pages
• Overview page 1
• Overview page 2
• Maintenance Page
• Conguration page 1
• Conguration Page 2
• System pages
Initial page
The page contains the product logo�
Page overview 1
For the number of GFW/GPC enabled it is possible:
• Enable / Disable individual GFW/GPC (access by
Maintenance/Admin level)
• Display the percentage power (P%) required by
analog or DCS/PLC signal. In the case of a manual
mode change the %P value�
• Display the instantaneous power (kW)
• Status of GFW/GPC power controller. Selecting the
status icon ( if red ) a pop up window will appare with
detailed information on all the alarms of the selected
GFW/GPC�
Page Alarms active
• Display of the digital ON/OFF command sent to the
individual GFW/GPC
Page Overview 2
For the number of GFW/GPC enabled it is possible:
• Displaying the GFW/GPC enable status
• Display of phase 1, phase 2 and phase 3 GFW/GPC
load currents (only the current values available for
each individual GFW/GPC are displayed)
• Display of the powers phase 1, phase 2 and phase
3 of the GFW/GPC (only the power values available
for each individual GFW/GPC are displayed)

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• Display of phase 1, phase 2 and phase 3 load
voltages of the GFW/GPC (only the voltage
values available for each individual GFW/GPC are
displayed)
Page maintenance
Page with access to Maintenance/Admin levels only.
From the page it is possible to disable a single GFW/GPC
from the load management algorithm� This could be the
case if you need to carry out maintenance operations�
It is possible to select between three GFW/GPC command
modes:
• Analog signal wired in GFW/GPC terminal board (the
enable signal for each power controller is a digital
input on its own terminal board)
• Modbus TCP network in case of DCS/PLC master
control device (the enable for each power controller
must be write from DCS/PLC in the dedicated
parameter)
• Manual from GSLM graphic pages (the enable of
each power controllers can be set from the Page
maintenance)
Page conguration 1
Page with access to Admin levels only� In the page it is
possible to set the total number of GFW/GPC managed
from GSLM (max 64, based on the model selected).
The following GSLM parameters can be congured:
• Set the number of power control Zones
• Enable Load Sharing Function
• Enable Load Shedding Fucntion
• Set the maximum total power limit value used by the
Load Shedding Function [kW]�
• Set Minium power pulse ON Time [s]
• Set Power Efcency Factor calculation period [s]
Page conguration 2
Page with access to Admin levels only
On the page for all congured GFW/GPC is possible:
• Set the theoretical power of the load (kW)
• Select the type of connection (single-phase / two-
phase / three-phase)
• Modify the identication name (default from 1 to 64)
• Congure the CEP parameter: safety value forced
by GFW/GPC in case of lack of communication with
GSLM

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80582_User Manual_GSLM_11-2020_ENG
Pages with access to Admin levels only�
From the System page the following main info are
available:
• Congure GSLM node IP address
• Check the status of Modbus TCP communication
• Select language (Default English)
• Password and user management
• View alarm history
• View settings history
Alarms active page
Opened by the icon
The active alarms list page displays descriptions and the
date/time of activation for all active alarms on the machine.
The alarms can be “communications alarms” or alarms
coming from the Power Controllers� There are four buttons
on the right (scroll up/down) to display the alarm message
lines that exceed monitor dimensions.
Alarms active page
The alarms coming from the GPC/GFW are listed in the
following dedicated page�
History alarms page
The historical alarms list page displays the descriptions,
state (ON / ACK), and date/time of activation of all historical
alarms recorded on the machine� There is a scroll bar on
the right (scroll up/down) to display the alarm message lines
that exceed monitor dimensions.
There is also a Clear button to reset the recorded historical
alarms�
History alarms page
History data page
This page lists, in chronological order, all of the changes
made on the machine�
Each change is shown with a reference to the active user at
the time of the change, the date and time of the change, a
description, the old data, and the new data�
History Data page
SYSTEM PAGES

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User login page
Through the icon
it’s possible to change the active user�
There are 3 access levels:
Level 0 Name: “operator” (Default password “operator”)
Level 1 Name: “maintenance” (Default password
“maintenance”)
Level 2 Name: “admin” (Default password “admin”)
The password must be digit from virtual keyboard from
VNC� It is invalid if digit from physical keyboard of VNC
Client�
The number of the active level is shown at the top of every
graphic page�
Pop-up User login
User manager page
This page allows to add, remove or change the password
to the archived users�
The page shows the list of archived users with password,
name and permitted access level�
Date hour page
On the date hour page, you can congure the date/time
shown on the graphics pages�
A eld is present in this page with information about the
status of the CPU that is useful in case of diagnostic�
Date hour page
Language page
The language page is designed to allow the future
selection of other languages�
At the moment the available language is English�
Language page

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80582_User Manual_GSLM_11-2020_ENG
Net conguration page
This page is useful for the conguration of ethernet ports.
ETH1 is dedicated to be connected, if necessary, to the
factory network ( default IP 192.168.1.100 ).
ETH2 is dedicated to connect the GFW/GPC units on the
automation network ( default IP 200.19.10.100 )
In this page it is possible to change the Modbus TCP slave
node address of the device (the default numebr node of
GSLM is 255)
In this page it is possible to change the Modbus TCP slave
node address of the device�
For the changes on the ethernet port is necessary a reboot
of the panel to apply the new conguration.
Net conguration page
Power graphs page
Up to 8 pens can be displayed simultaneously on trend pages�
Sampling time of all variables can be congured in seconds.
The Trend page shows the trend of 8 variables of the Power
outputs over time� The pages have a series of buttons that let
you zoom+, zoom-, scroll+ and scroll- the curves on the page.
Power graphs page
The curve displayed on the trend page is matched with
the variable to be represented on a dedicated page that is
accessed by pressing the bottom of such page at the legend
of the displayed curves�
Power graphs page
Power Efciency Factor graph page
The “Power Efciency Factor” calculation, depending on
the real Power distribution trought the Power Controllers
in the network, is shown in the Power Effcicinecy Factor
graph� The more the value is close to one, the better is the
efciency of the system�

14 80582_User Manual_GSLM_11-2020_ENG
Data Log conguration and USB
exporting page
In this page are present a series of commands that allow
the exporting of storage data like DataLog.
The data logger are temporary recordings of all the Power
values ( in kW ) of all the zones� The sample time of
recording can be setting from minimum 1 to maximum 999
seconds�
The csv les exporting it’s allowed by USB�
Data log conguration page

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80582_User Manual_GSLM_11-2020_ENG
Dimension
GSLM assembly dimension
Dimensions in mm
217
232
203
44.6
33
16.3118
3
6 134.3
5.5
Space for ventilation
The open spaces shown in gray are recommended with static ventilation� These spaces may be reduced with forced
ventilation�
Dimensions in mm
Attention: the temperature in the compartment containing the internal cabinet control panel must never exceed 55°C.
HARDWARE

16 80582_User Manual_GSLM_11-2020_ENG
Assembly and Installation
Hole dimensions� For correct installation, observe the
dimensions of the templates shown in the illustration
Attention: the panel on which the internal cabinet control
panel is mounted has to have the following characteristics:
• Be sufciently stiff and strong so that it does not
bend during use;
• Be between 1 and 6 mm thick, to allow the fastening
of the device with the terminals supplied�
Dimensions in mm
18
26.6
217
15
5.5
Protection against inltrations of water
The internal cabinet control panel offers an IP20 protection
level�
If the product has to be used in an environment in which a
protection level higher than IP20 is required, this must be
guaranteed by the cabinet that hosts the product itself�
Vibration
The internal cabinet control panel can support vibrations:
• From 5 to 9 Hz: sinusoidal 3�5 mm constant;
• From 9 to 150 Hz: sinusoidal with acceleration equal
to 1 G
Should the device be mounted on a support that exceeds
these limits it is necessary to envisage a system for the
suspension and mitigation of the vibrations�
Minimum spaces for ventilation
The temperature of the compartment that houses the
internal cabinet control panel must not exceed 55°C.
The free spaces for ventilation show the minimum free
distances recommended in the installation of the device in
a closed compartment
Positioning
The internal cabinet control panel has to be positioned in
order to guarantee the following conditions:
• If necessary, screen direct rays, using an antiglare
shutter for example;
• There must be no sudden temperature changes;
• There must be a low explosion risk: it can be
connected to elements that operate in environments
with a hazardous atmosphere (ammable or
explosive) only through appropriate and suitable
types of interface, compliant to the safety standards
in force;
• Low presence of magnetic elds.
Fastening
The internal cabinet control panel can be installed in two
ways:
• Horizontal on DIN 35 mm track:
-Install the 2 brackets for the DIN 35
track� Fasten the product and press
hard to complete the operation, rotating
downwards�
• Vertical mounting:
• Prepare the M5 threaded holes, done with the
template, position the product and screw in place�

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80582_User Manual_GSLM_11-2020_ENG
Warning: install locking washers to prevent the screws from loosening!

18 80582_User Manual_GSLM_11-2020_ENG
The system is powered with ONE (1) power supply.
Internal cabinet control panel
+24Vdc
0V
PE
PS AUXILIARY
DE VICES
AC Line
Ferrite
Bead
MAIN POWER SUPPLY
To power the system correctly, make sure that:
• The power supply has the power needed to run the
system and any additional resources connected to it�
• Ground the power supply (GND) with a wire that is
straight and as short as possible (PE).
• Insert the ferrites into the power supply cables as
close as possible to the GSLM Control Panel�
• The system power supply line must have a different
path from the plant and machine power cables�
Ground the GSLM ground terminal and with a wire that is
straight and as short as possible to the (PE) point.

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80582_User Manual_GSLM_11-2020_ENG
Technical data
GSLM technical data table
POWER SUPPLY
Operating voltage 24 VDC ±25%
Current draw
(at 24 VDC) 500 mA max
Power dissipation 12 W max
Protections Polarity inversion
Short circuit
Connection 3-pin polarized removable connector
Screw terminals, max cable section 2.5 mm2
CONNECTIONS
Ethernet port (ETH) Number of channels: 2
Connector: RJ45
Speed: 10 / 100 / 1000 Mbit/s
Signals: green connection LED, yellow data LED
USB port Number of ports: 2 max
Connector: type A
Standard: USB 2�0
Protection: overload
COMMUNICATION
PROTOCOLS
Ethernet Modbus TCP/IP Master/Slave
VIEWING ELEMENTS
Diagnostics PW LED (yellow): power supply on
RN LED (green): SW program state
LED E1 (red): HW Watchdog state
LED E2 (red): SW program error
MICROPROCESSOR Type and frequency ATOM E640 1 GHz
ATOM E660, 1�3 GHz
MEMORY System 512 MB, DRAM type DDR II
Mass 2 GB Flash memory
AMBIENT CONDITIONS
Operating temperature 0 ... +55 °C (as per IEC 68-2-14)
Storage temperature -20 ... +70 °C (as per IEC 68-2-14)
Relative humidity max 95% RH non condensing (as per IEC 68-2-3)
Vibrations 5 to 9 Hz: sine constant 3�5 mm
10 to 150 Hz: sine acceleration 1G
ASSEMBLY Mounting inside the control panel, horizontally with the DIN bar
or vertically with xing screws.
PROTECTION LEVEL IP 20 (as per IEC 68-2-3)
WEIGHT 1,250 kg
CE STANDARDS
EMC
(electromagnetic
compatibility)
Conforms to Directive 2014/30/EU
EN61131-2: Programmable controllers
Part 2: Equipment requirements and tests�

20 80582_User Manual_GSLM_11-2020_ENG
Connections
Inputs, Outputs and signals
12345678
9101112
1314
No Description Connector / indicator Notes
1 24 VDC ± 25% power supply input Removable polarized terminal block
2 LED PW (yellow): power ON
RN (green): SW program status
E1 (red): HW Watchdog status
3Ethernet to be connected to GFW/
GPC
RJ45
4 Ethernet for LAN connection RJ45
5 NOT USED
6 NOT USED
7 NOT USED
8 NOT USED
9 Porta USB Type A
10 Porta USB Type A
11 NOT USED
12 NOT USED
13 NOT USED
14 NOT USED
Power
The GSLM internal cabinet control panel must be
connected to a 24 Vdc power supply unit�
The same 24 VDC power supply can feed other devices as
well� Make sure that the current issued by the power supply
is higher than the total maximum current absorbed by all
the devices connected�
230 VAC 24 VDC
-
+