gefran 2400 User manual

1
80290C_MHW_2400_0908_ENG
2400
FAST INDICATOR / INTERCEPTOR
Software version 1.4x
code 80290C / Edition 06 -09/08 ENG
INSTALLATION AND
OPERATION MANUAL
GENERAL INDEX
Page
Graphic symbols used 2
1 Preliminary instructions 2
General description 2
Basic version
Indicator / Interceptor 2
Options 2
Operator intefrace 3
Electrical interface 3
Preliminary warnings 3
2 Installation and connection 4
Electrical power supply 4
Notes concerning electrical safety and
Electromagnetic compatibility 4
Advice for correct installation
for EMC 5
Instrument power supply 5
Inputs and outputs connection 5
Dimensions and cut-out 6
Installation with panel mounting 6
Warnings and instructions for
mounting to the panel 6
Nominal ambient conditions 6
Electrical connections 7
3 Functions 17
Operator interface 17
General operating notes 18
Navigating through the
Indicator / Interceptor 19
4 Configuration and programming 21
Application notes 39
HOLD function 39
FLASH function 39
Alarms 39
Software ON/OFF switching function 39
String assigned to an alarm 40
5 Technical specifications 41
6 Maintenance 42
Cleaning 42
Repairs 42
Checking the jumpers 42
Troubleshooting Guide 42
7 Technical-Commercial information 43
Order code 43
Accessories
RS232/TTL interface for Gefran
Instrument configuration 43
Appendix 44
Block Diagrams 49
Functional diagram 50
Examples of custom linearization 56
The contents of each section are summarized
immediately following the section heading

280290C_MHW_2400_0908_ENG
Graphic symbols used
To distinguish between the type and importance of the information provided in these instructions for use, graphic
symbols have been used as a reference to make interpreting the information clearer.
Indicates the contents of the various manual sections,
the general warnings, notes, and other points to
which the reader's attention should be drawn.
Indicates a particularly delicate situation that
could affect the safety and correct working
operation of the controller, or a rule that must be
strictly observed to avoid dangerous situations
Indicates a condition of risk for the safety of the
user, due to the presence of dangerous voltages
at the points shown
Indicates a suggestion based on the expe-
rience of the GEFRAN Technical Staff,
which could prove especially useful under
given circumstances
Indicates a reference to Detailed Technical
Documents available on the GEFRAN web
site www.gefran.com
1 • PRELIMINARY INSTRUCTIONS
This section contains information and warnings
of a general nature which should be read befo-
re proceeding with controller installation,
configuration and use.
General Description
The instrument is appropriate for acquisition of signals
with high variation speed. It has two main analog inputs
for many applications, including differential measure-
ments. The inputs are configurable from the keyboard
and accept standard linear signals (and custom lineari-
zed signals), as well as signals from pressure probes,
load cells, potentiometers, TC, RTD.
They offer an exclusive combination of performance,
reliability, and applicative flexibility. In particular, this
new line of Gefran indicators/alarm units is the ideal
solution for sectors demanding high performance and
continuity of service, with:
• pressure measurements and setpoints on extrusion
lines and injection presses for plastics
• pressure measurements and setpoints
(absolute or differential)
• position measurements and setpoints
• variable setpoints in fast processes and automations,
with retransmission
The instrument also has 2 digital inputs for reset, calibra-
tion, and hold functions.
The outputs (up to 4) are relay or logic, and are configu-
rable.
An MD8 expansion is available as an alternative to out-
puts 3 and 4 for 8 additional setpoint outputs.
An optional, high-resolution, optically isolated analog out-
put is available for analog retransmission, process varia-
ble value, peak value, setpoint, differential value.
Indicator/Alarm unit in Basic Version
(mod. 2400-0-0-4R-0-X)
• 1 universal input for strain gauge,
potentiometer, TC thermocouples, RTD 2/3 wires and
linears in current and voltage with accuracy better
than 0.1% f.s.
•2 auxiliary inputs for linears in current and voltage,
potentiometers
•1 power supply for transmitters
•2 digital inputs configurable NPN or PNP
•1 probe power supply selectable for strain gauge,
potentiometers and transmitters
•4 outputs: OUT1, OUT2, OUT3, OUT4 relay
Options
•second universal input
(useful for differential measurements)
•1 analog retransmission output
•1RS485 optically isolate serial interface
•MD8 expansion interface as alternate to outputs 3
and 4.

3
80290C_MHW_2400_0908_ENG
Operator Interface
All the operator interface devices are concentrated on
the controller faceplate with IP54 level protection.
• 6 buttons to be used for regulation / manual selection
• 1 red/green five-digit displays
• 1 red two-digit displays
(Index for configuration parameters)
• 10 red LEDs to indicated setpoint state
• 4 red/green led for configurable indication
Electrical Interface
All connection terminals (power supply, inputs, outputs,
options) are grouped together on the back of the
instrument.
For technical specifications and performance details
refer to Section 5 "Technical Specifications”.
Preliminary Warnings
The following preliminary warnings should be
read before installing and using the series 2400
indicator/interceptor. This will allow the controller
to be put into service more quickly and will
avoid certain problems which may mistakenly be
interpreted as malfunctions or limitations of the
controller.
• Immediately after unpacking the instrument, make a
note of the order code and the other identification
data given on the label affixed to the outside of the
container and copy them to the table below.
These details must always be kept close at hand and
referred to the personnel involved in the event of help
from Gefran Customer Service Assistance.
• Check also that the instrument is complete and has
not been damaged at all during transit, and that the
package contains not only the controller and these
Instructions for Use, but also the two brackets for
fixing to the panel and the dust protection seal - see:
Installation with Panel Fixing in Section 2.
Any inconsistencies, omissions or evident signs of
damage should be reported immediately to your
Gefran sales agent.
• Check that the order code corresponds with the
configuration requested for the application the
instrument is needed for, referring to Section 7:
“Technical - Commercial Information”.
• No. and Type of Inputs/Outputs available
• Presence of the necessary options and
accessories
• Mains voltage supply
Example: 2400 – 0 – 0 – 4R – 2 – 1
Model 2400
Single main input
None retransmission output
4 relay outputs
Digital Communication: RS485
Power supply 100...240Vac/dc
• Before installing the instrument serie 2400 on the
control panel of the machine or host system, refer to
the paragraph "Dimensions and Cut-out" in Section 2
“Installation and Connection”.
• Where configuration by PC is provided for, make sure
the interface RS232 cable is available and the CD-
ROM containing the WINSTRUM software. For the
order code refer to Section 7 “Technical - Commercial
Information”.
Users and/or system integrators who wish to
know more about the concepts of serial commu-
nication between standard PC and/or Gefran
Industrial PC and Gefran Programmable
Instruments, can access the various technical
reference Documents in Adobe Acrobat format
available in the Download section of the Gefran
Web Site www.gefran.com including:
• Serial Communication
• MODBus Protocol
In the same Download section of the Gefran Web
Site www.gefran.com the instrument serie 2400
reference manual is available inAdobeAcrobat
format, containing a detailed description of all the
adjustable parameters and procedures.
In the event of presumed instrument malfunction,
before contacting Gefran Technical Service
Assistance, refer to the Troubleshooting Guide
given in Section 6 "Maintenance", and if
necessary refer to the F.A.Q. Section (Frequently
Asked Questions) on the Gefran Web Site
www.gefran.com
SN: ......................... (Serial n°)
CODE: ......................... (Finished product code)
TYPE: ......................... (Order Code)
SUPPLY: ......................... (Type of electrical power supply)
VERS: ......................... (Software version)

480290C_MHW_2400_0908_ENG
2 • INSTALLATION AND CONNECTION
This section contains the instructions necessary
for correct installation of the instrument 2400
into the machine control panel or the host
system and for correct connection of the control-
ler power supply, inputs, outputs and interfaces.
Before proceeding with installation read the
following warnings carefully!
Remember that lack of observation of these
warnings could lead to problems of electrical
safety and electromagnetic compatibility, as
well as invalidating the warranty.
Electrical power supply
• the instrument is NOT equipped with an On/Off switch:
the user must provide a two-phase disconnecting
switch that conforms to the required safety standards
(CE marking), to cut off the power supply upstream of
the instrument.
The switch must be located in the immediate vicinity of
the instrument and must be within easy reach of the
operator.
One switch may control more than one controller.
• if the instrument is connected to NOT isolated electrical
equipment (e.g. thermocouples), the earth connection
must be made with a specific conductor to prevent the
connection itself from coming directly through the
machine structure.
• if the instrument is used in applications with risk of
damage to persons, machinery or materials, it is
essential to connect it up to auxiliary alarm
equipment. It is advisable to make sure that alarm
signals are also triggered during normal operation.
The instrument must NOT be installed in flammable or
explosive environments; it may be connected to
equipment operating in such atmospheres only by
means of appropriate and adequate types of
interface, conforming to the applicable safety
standards.
Notes Concerning Electrical Safety and
Electromagnetic Compatibility:
CE MARKING: EMC Conformity (electromagnetic
compatibility)
in accordance with EEC Directive 89/336/CEE and follo-
wing modifications.
The instrument series 2400 are mainly designed to ope-
rate in industrial environments, installed on the switch-
boards or control panels of productive process machi-
nes or plants.
As regards electromagnetic compatibility, the strictest
generic standards have been adopted, as indicated in
the table below.
BT Conformity (low voltage) in accordance with
Directive 2006/95/CE.
EMC conformity has been tested with the following
connections.
Function Cable type Length
Power supply cable 1mm21m
Relay output cables 1mm23,5m
Serial connection wire 0,35mm23,5m
Thermocouple input 0,8mm2compensated 5m
Strain gauge input, potentiometers, linears,
“PT100” temperature resistance 1mm23m
Control and retransmission analog outputs 1mm23,5m
Digital Inputs / Outputs 1mm23,5m

5
80290C_MHW_2400_0908_ENG
Advice for Correct Installation for EMC
Instrument power supply
• The power supply to the electronic equipment on the
switchboards must always come directly from an
isolation device with a fuse for the instrument part.
• The electronic instruments and electromechanical
power devices such as relays, contactors, solenoid
valves, etc., must always be powered by separate
lines.
• When the electronic instrument power supply is
strongly disturbed by the commutation of transistor or
power units or motors, an isolation transformer
should be used for the controllers only, earthing the
screen.
• It is essential that the plant has a good earth
connection:
- the voltage between neutral and earth must not be >1V
- the Ohmic resistance must be < 6Ω;
• If the mains voltage fluctuates strongly, use a voltage
stabilizer.
• In the proximity of high frequency generators or arc
welders, use adequate mains filters.
• The power supply lines must be separate from the
instrument input and output ones.
Inputs and outputs connection
• The externally connected circuits must be doubly
isolated.
• To connect the analogue inputs and analog outputs
the following is necessary:
- physically separate the input cables from those of the
power supply, the outputs and the power connections.
- use woven and screened cables, with the screen
earthed in one point only.
• To connect the relay outputs
(contactors, solenoid valves, motors, fans, etc.), fit
RC groups (resistance and condensers in series) in
parallel to the inductive loads that operate in
Alternating Current.
(Note: all the condensers must conform to VDE
(class X2) standards and withstand a voltage of at
least 220V AC. The resistances must be at least 2W).
• Fit a 1N4007 diode in parallel with the coil of the
inductive loads that operate in Direct Current.
GEFRAN S.p.A. declines all responsibility for
any damage to persons or property caused
by tampering, neglect, improper use or any
use which does not conform to the characte-
ristics of the controller and to the indica-
tions given in these Instructions for Use.
Generic standards, emission standard for residential
commercial and light industrial environments
Generic standards emission standard for industrial environment
Emission AC mains
Radiated emission
EN 61000-6-3
EN 61000-6-4
EN 61000-6-3
EN 61000-6-4
CISPR-16-1-4
CISPR-16-2-3
CEI R210-010
Classe B
Classe A
EMC EMISSION
EMC IMMUNITY
Generic standards, immunity standard of industrial environments
Electrostatic discharge immunity
Radiated radio frequency electromagnetic field immunity test
Conducted disturbances immunity
Electrical fast transient/burst immunity test
Surge immunity test
Power frequency magnetic field immunity test
Voltage dips, short interruptions and voltage immunity tests
EN 61000-6-2
EN 61000-4-2
EN 61000-4-3 +A1
EN 61000-4-6
EN 61000-4-4
EN 61000-4-5
EN 61000-4-8
EN 61000-4-11
± 4 kV contact discharge
± 8 kV air discharge
10 V/m amplitude modulated
80 MHz-1 GHz
10 V/m amplitude modulated
1.4 GHz-2 GHz
10 V/m amplitude modulated
0.15 MHz-80 MHz
± 2 kV power line
± 2 kV signal line
Power line-line ± 1 kV
Power line-earth ± 2 kV
Signal line-earth ± 1 kV
100 A/m
100%U, 70%U, 40%U,
LOW VOLTAGE DIRECTIVE SAFETY
Safety requirements for electrical equipment for measurement,
control and laboratory use EN 61010-1

680290C_MHW_2400_0908_ENG
Dimensions and cut-out
108
96 115
44,5
92
70
48
10
170
Installation with panel mounting
As well as the actual instrument and these instructions
for use, the controller package also contains:
• 2 panel fixing brackets (A)
• 1 protective seal against dust and water spray (B)
Fit the instrument to the panel as shown in the figure.
Warnings and instructions for mounting to the panel
Instructions for installation category II,
pollution level 2, double isolation.
• only for models with 20...27Vac/dc power supply:
supply from Class 2 or low voltage limited energy
source
• the power supply lines must be separate from the
controller input and output ones
• group the instruments together keeping them separate
from the powered part of the relay
• do not install high-power remote switches, contactors,
relays, thyristor power units (especially the “phase
angle” type), motors, etc. in the same switchboard
• avoid dust, humidity, corrosive gasses and heat
sources
• do not block the ventilation holes: the working
temperature must be between 0...50°C
• surrounding air: 50°C
• use 60/75°C copper (Cu) conductor only, wire size
range 2x N. 22 - 14AWG, Solid/Stranded
• use terminal tightening torque 0.5Nm
Nominal ambient conditions
Before supplying the Indicator with power,
make sure that the mains voltage is the
same as that shown in the last number of
the order code.
Example:
2400 – x – x – x – x – 1 = 100..240Vac/dc
2400 – x – x – x – x – 0 = 20..27Vac/dc
A
B
A
B
Altitude Up to 2000m
Working/storage 0..50°C/-20...70°C
temperature
Non condensing 20...85%
relative humidity

7
80290C_MHW_2400_0908_ENG
Electrical Connections (Mod. 2400 - 0 - x - x - x - x)
1
12
234567891011
13141516171819202122
33323130292827262524
When making connections, always use wire appropriate to the voltage and current limits indicated in
Section 5 – Technical Characteristics.
If the instrument has faston contacts, they must be protected and isolated.
If it has screw contacts, the wires must be attached at least in pairs
-0V
+IN4
-0V
+IN3
+24V transmitter supply
+
probe supply
-
~
power supply
90-260Vac / 18-30Vac/dc
~
no/nc +
c -
+
Rtd1 CAL1
-
+
IN1
-
33323130292827262524
GND RX -
A(+) Tx +
B(-) Tx -
-OUT W
+
2-wires 4-wires
Rx +
RS485
no/nc +
OUT 3
OUT 4
DI2
DI1 +
+
-+ no/nc
- c
+ no/nc OUT 2
OUT 1
GND
Tx
Rx
RS232
MD8
D
Gnd
CK

880290C_MHW_2400_0908_ENG
1
2
3
4
7
9/11
+
+
+
S
Input IN1 TC - Thermocouple
IN1 linear input with three-wire transmitter powered by instrument
IN1
Transmitter power supply
PT100 for possible
compensation of exter-
nal cold junction
Available thermocouples:
J, K, R, S, T
(B,E, N, L, U, G, D, C possible by inserting
custom linearization)
- Respect polarity
- For extensions, use compensated wire sui-
table to the CT utilized
Select the probe accordiing to transmitter
type
IN1 linear input with two-wire transmitter powered by instrument
1
2
3
4
7
9/11
+
+
+
IN1
24V Transmitter power supply
1
2
3
4
5
6
+
T
IN1
4...20mA
24V
Electrical Connections (Mod. 2400 - 0 - x - x - x - x)

9
80290C_MHW_2400_0908_ENG
IN1 Linear input (I)
1
2
+
Linear input in DC
0/4...20mA, Ri = 50Ω
IN1 Linear input (V)
1
2
+
Linear input in DC
± 60mV Ri > 10MΩ
± 100mV Ri > 10MΩ
± 1V Ri > 2MΩ
± 5V Ri > 2MΩ
± 10V Ri > 2MΩ
IN1 PT100 input
1
2
3
4
5
6
1
2
3
4
T T
+
2-wire connection 3-wire connection
Use wires with adequate sec-
tion (min 1 mm2)
IN1
IN1
IN1
IN1 potentiometer input
1
2
3
4
5
6
+
+
IN1
IN1 Strain-gauge input 4/6 wires
1
2
3
4
5
6
+
+
+
Strain-gauge sensitivity 1,5...4mV/V
Probe power supply
5/10V
Green
White
Black or Yellow
Red
Blue
Brown or
Orange
CAL
CAL
- Exc
+ Exc
IN1
Potentiometer
R ≥100Ω
Probe power supply
2,5V
Electrical Connections (Mod. 2400 - 0 - x - x - x - x)

10 80290C_MHW_2400_0908_ENG
Electrical Connections (Mod. 2400 - 1 - x - x - x - x)
1
12
234567891011
13141516171819202122
33323130292827262524
-0V
+IN4
-0V
+IN3
+24V transmitter supply
+
probe supply
-
~
power supply
90-260Vac / 18-30Vac/dc
~
no/nc +
c -
+
IN2
-
+
IN1
-
33323130292827262524
Gnd RX -
A(+) Tx +
B(-) Tx -
-OUT W
+
2-wires 4-wires
Rx +
RS485
no/nc +
OUT 3
OUT 4
DI2
DI1 +
+
-+ no/nc
- c
+ no/nc OUT 2
OUT 1
Gnd
Tx
Rx
RS232
MD8
D
Gnd
CK
++
CAL2 Rtd2 Al.P2
--
++
CAL1 Rtd1 Al.P1
--