Gefran Gtf plus User manual

80960_MHW_GTF_01-2012_ENG

GTF Plus

ADVANCED SOLID STATE RELAYS COMMUNICATION WITH MODBUS

INSTALLATION AND

OPERATION MANUAL

code 80960 - 01-2012 - ENG

INDEX

GRAPHIC SYMBOLS

To differentiate the type and importance of the information in this User Manual, graphic reference symbols are used to make such information

easier to interpret.

1 Preliminary instructions 2

1.1 Profile

1.2 General description

1.3 Preliminary instructions

2 Installation and Connection 4

2.1 Electrical power supply

2.2 Notes on electrical safety and

electromagnetic compatibility

2.3 Recommendations for correct installation for

purposes of EMC

2.4 Dimensions

2.5 Installation

2.6 General description GTF 25-120A

2.7 General description GTF 150-250A

2.8 Cleaning/checking or replacing the fan

for GTF 150-250A

2.9 Substitution of Internal Fuse

(Option only for GTF 150-250A)

3 Electrical connections 11

3.1 Power connections

3.2 Connections input/output 25-120A

3.3 Connections input/output GTF 25-120A

3.4 Functions of indicator leds

3.5 Control connectors

3.6 Configuration TTL port (GTF standars)

3.7 Serial comunication port Modbus RS485 (option)

3.8 Connection example: comunication ports

3.9 Connection example: power section

4 Installation of serial network 29

4.1 “AUTOBAUD SERIAL” sequence

5 Technical Characteristics 31

5.1 Derating Curves GTF without electronic fuse

(with SCR)

5.2 Derating Curves GTF with electronic fuse

(with IGBT)

6 Technical-Commercial information 36

6.1 Accessories

6.2 Fuses / Fuseholders

Indicates contents of sections, general instructions, notes, and

other points to which the reader’s attention needs to be called.

Indicates a particularly delicate situation that could affect

the safety or correct operation of the controller, or an

instruction that MUST be followed to prevent hazards.

Indicates a risk to the user’s safety due to high voltage at the

points indicated.

Indicates a suggestion based on the experience of

GEFRAN’s Technical Personnel that could be

especially useful under certain circumstances.

Indicates a reference to Detailed Technical

Documents available on the GEFRAN website

www.gefran.com.

280960_MHW_GTF_01-2012_ENG

1.1 Profile

The “ GTF adv” series of microprocessor advanced solid state

power units controls, in compact and optimized size, high electric

powers with different types of heating elements, single-phase,

biphase or triphase.

Current levels range from 40A to 250A, nominal voltage from 480

VAC to 600VAC.

The command input is congurable and accepts 0-10V, 0/4-20mA

signals, potentiometer, logic signals, including with PWM modes

for cost effective solutions.

The device can also be operated via Modbus RTU serial com-

munication, with IN/OUT chain connections facilitated by plug-in

RJ10 (telephone) connectors.

The several trigger modes are software congurable and provide:

- ZC: Zero Crossing constant cycle time (settable in range

1-200sec), for conventional loads

- BF: Burst-Firing, Zero crossing with optimized minimum cycle

time, for systems with low thermal inertia, medium-wave IR lamps

- HSC: Half Single Cycle Zero Crossing corresponds to Burst

Firing that manages single semi-cycles of conduction or stop

cycles, useful for short-wave IR lamps, reduces ickering and li-

mits generation of EMC noise on the power line (applied only to

single-phase load or open delta).

- PA: Phase angle control, useful for short-wave IR lamps, tran-

sformer primaries. Completely eliminates ickering of load la-

ments, but generates EMC noise on power line (harmonics).

Soft Start and soft stop ramp functions can be assigned to these

controls with limitation of current peaks and/or maximum RMS

current level.

Thanks to sophisticated Hardware and Software solutions, you

can precisely control different types of loads.

Phase angle control (the only control method that completely

eliminates IR lamp ickering), matched with current, voltage, or

load power feedback functions, allows the easy use of “critical”

applications such as (for example), special resistors such as spe-

cial Super Khantal™ heating elements, Silicon Carbide resistors,

or transformer primaries either single-phase or triphase.

GTF runs complete diagnostics of current, voltage, power, and

temperature levels:

Current Diagnostics:

- Total and partial load interrupt alarm

- Self-learn function of alarm limit for interrupted load

- Alarm for SCR in short circuit

- Alarm for load in short circuit or overcurrent

Voltage Diagnostics:

- Alarm for absence of phase

Temperature Diagnostics:

- Alarm for over temperature of power module

Power control with Soft start ramp limits load, optimizes the con-

sumptions and increases the load operating duration.

The internal resettable “electronic fuse” is an exclusive option:

it lets you avoid extra-rapid fuses and greatly reduces machine

downtimes and cost caused by looking for and replacing such

fuses.

Device parameters can be congured from PC, by means of a sim-

ple conguration SW which lets you save all parameters in a con-

guration le that is easy to manage and to copy to other devices.

Moreover, an RS485 serial connection of GTF is offered with

Modbus RTU protocol to control currents, voltages, powers, load

status, and device status from the supervisor terminal (HMI) or

PLC.

The section contains general information and

warnings to be read before installing, configuring and

using the controller.

1.2 General DescriPtion

GTF is single-zone advanced solid state power unit, extremely

compact, equipped with different optional functions; it offers an

exclusive combination of performance, reliability, and flexibility.

In particular, this new line of Gefran controllers is the ideal

solution for sectors demanding high performance and continuity

of service, such as:

• Thermoforming

• Blowing

• Hot runners for injection presses

• Texturizing of fibers

• Heat treatment furnaces

• Woodworking machines

• Glass tempering furnaces

The modules series GTF controllers are based on an extremely

versatile hardware and software platform, with options to select

the best I/O configuration for your system.

GTF is used for the power control of single-phase and 2-phase

loads, including resistive loads with high and low temperature

coefficient, short wave IR lamps, or transformer primaries.

Attention: the description of programming and

configuration parameters are contained in the

“Programming and configuration” manual,

downloadable from the website www.gefran.com

1 • PRELIMINARY INSTUCTIONS

80960_MHW_GTF_01-2012_ENG

1.3 Preliminary instruction

Read the following preliminary instructions before

installing and using the GTF modular power

controller.

This will make start-up faster and avoid some

problems that could be mistakenly interpreted as

malfunctions or limitations of the controller.

Immediately after unpacking the unit, check the order code

and the other data on the label attached to the outside of the

container.

Write them on the following table.

This data must always be available and given to Gefran

Customer Care representatives are available if technical service

is needed. Check that the controller is in perfect condition,

was not damaged during shipment, and that the package also

contains the “Configuration and Programming” manual.

Immediately report any errors, shortages, or signs of damage to

your Gefran dealer.

Check that the order code matches the configuration requested

for the intended application by consulting the section:

“Technical-Commercial Information.”

Example: GTF 90 - 480 - 0 - 1 - 0 - M

Model

Nominal current

Nominal voltage

Control option, Absent

Diagnostic option: HB

Fuse: absent

Serial Modbus

See paragraph 2.1 “ Dimensions and mounting” before installing

the GTF on the machine/host system control panel.

To configure the PC use the SW Gefran GF-Express kit and the

relative connection cable.

For the order code, see Section:

“Technical-Commercial Information”.

Users and/or system integrators who want detailed

information on serial communication between

Gefran standard and/or industrial PCs and Gefran

Programmable Instruments can access Technical

Reference Documents on serial communication

and MODBus protocol, etc., in Adobe Acrobat

format on the Gefran website www.gefran.com:

• Serial Communication

• MODBus Protocol

Before calling Gefran Customer Care in case of assumed

malfunctions, please see the Troubleshooting Guide in the

“Maintenance” section and, if necessary, the F.A.Q. (Frequently

Asked Questions) section on the Gefran website

www.gefran.com

SN............................... (Serial number)

CODE ......................... (Product code)

TYPE........................... (Order code)

SUPPLY...................... (Power Supply)

VERS. ......................... (Firmware version)

480960_MHW_GTF_01-2012_ENG

This section contains the instructions needed for

correct installation of GTF controllers on the

machine/host system control panel and for correct

connection of the power supply, inputs, outputs and

interfaces.

CAREFULLY READ THE FOLLOWING WARNINGS

BEFORE INSTALLING THE INSTRUMENT!

Disregard of such warnings could create

electrical safety and electromagnetic

compatibility problems, as well as void the

warranty.

2.1 Electrical Power suPPly

• the controller DOES NOT have an On/Off switch: the user

must install switch/isolator conforming to safety requisites (CE

mark) to cut off the power supply up-line of the controller.

The switch must be installed in the immediate vicinity of the

controller in easy reach of the operator.

A single switch can be used for multiple devices.

* the earth connection must be made with a specific lead.

• if the product is used in applications with risk of harm to

persons or damage to machines or materials, it MUST be

equipped with auxiliary alarm devices.

It is advisable to provide the ability to check for tripped alarms

during regular operation.

DO NOT install the product in rooms with hazardous

(inflammable or explosive) atmosphere; it may be connected

to elements that operated in such atmosphere only by means

of appropriate interfaces that conform to current safety

standards.

2.2 Notes on electrical safety anD

electromaGnetic comPatibility:

2.2.1 CE MARKING: EMC

(electromagnetic compatibility) conformity

in compliance with Directive 2004/108/CE and following

modifications.

Series GTF controllers are mainly intended for industrial

use, installed on panels or control panels of production

process machines or systems.

For purposes of electromagnetic compatibility, the most

restrictive generic standards have been adopted, as shown

on the table.

2.2.2 LV (low voltage) conformity

in compliance with Directive 2006/95/CE.

EMC conformity has been verified with the

connections indicated on table 1.

2.3 RecommenDations for correct installation

for PurPoses of EMC

2.3.1 Instrument power supply

• The power supply for the electronic instrumentation on the

panels must always come directly from a cut-off device with

fuse for the instrument part.

• Electronic instrumentation and electromechanical power

devices such as relays, contactors, solenoids, etc., MUST

ALWAYS be powered by separate lines.

• When the power supply line of electronic instruments is

heavily disturbed by switching of thyristor power groups or

by motors, you should use an isolation transformer only for

the controllers, grounding its sheathing.

• It is important for the system to be well-grounded:

- voltage between neutral and ground must not be > 1V

- Ohmic resistance must be < 6Ω;

• If the grid voltage is highly unstable, use a voltage stabilizer.

• In proximity of high-frequency generators or arc welders,

use adequate grid filters.

• The power supply lines must be separate from instrument

input and output lines.

•Supply from Class II or from limited energy source

2.3.2 Input and output connections

Before connecting or disconnecting any connection, always check

that the power and control cables are isolated from voltage

Appropriate devices must be provided: fuses or automatic

switches to protect power lines.

The fuses present in the module function solely as a protection

for the GTF semiconductors.

• Connected outside circuits must be doubly isolated.

• To connect analog inputs, strain gauges, linears, (TC, RTD),

you have to:

- physically separate the input cables from those of the

power supply, outputs, and power connections.

- use braided and shielded cables, with sheathing grounded

at a single point.

2.3.3 Installation notes

Use the extra-rapid fuse indicated in the catalogue according to

the connection example equipped.

- Moreover, the applications with solid-state units require a safe-

ty automatic switch to section the load power line.

To ensure maximum reliability, the device must be correctly

installed in the panel in such a way as to obtain adequate heat

exchange between the heat sink and the surrounding air under

conditions of natural convection..

Fit the device vertically (maximum angle 10° to the vertical

axis) see gure 3

• Vertical distance between a device and the panel wall

>100mm

• Horizontal distance between a device and the panel wall at

last 10mm

• Vertical distance between a device and the next one at last

300mm.

• Horizontal distance between a device and the next one at last

10mm.

Check that the cable holder runners do not reduce these di-

stances, in this case t the cantilever units opposite the panel

so that the air can ow vertically on the dissipator without any

obstacles.

2 • INSTALLATION AND CONNECTION

80960_MHW_GTF_01-2012_ENG

• dissipation of device thermic power with effects on installation

room temperature.

• thermal power dissipation with limits on installation room tem-

perature.

• requires exchange with external air or an air conditioner to tran-

sfer dissipated power outside the panel.

• maximum limits of voltage and derived power of transients on

the line, for which the solid state power unit contains protective

devices (based on the model).

• presence of dispersion current in GTF in non-conducting state

(current of a few mA due to RC Snubber circuit to protect the

thyristor).

GEFRAN S.p.A. assumes no liability for any

damage to persons or property deriving from

tampering, from incorrect or improper use, or

from any use not conforming to the

characteristics of the controller and to the

instructions in this User Manual.

Generic standards, immunity standard for industrial environments EN 60947-4-3

ESD immunity EN 61000-4-2 4 kV contact discharge

8 kV air discharge

RF interference immunity EN 61000-4-3 /A1 10 V/m amplitude modulated

80 MHz-1 GHz

10 V/m amplitude modulated

1.4 GHz-2 GHz

Conducted disturbance immunity EN 61000-4-6 10 V/m amplitude modulated

0.15 MHz-80 MHz

Burst immunity EN 61000-4-4 2 kV power line

2 kV I/O signal line

Surge immunity EN 61000-4-4/5 Power line-line 1 kV

Power line-earth 2 kV

Signal line-earth 2 kV

Signal line-line 1 kV

Magnetic elds immunity Test are not required.

Immunity is demonstrated by

the successful completion of

the operating capability test

Voltage dips, short interruptions and voltage immunity tests EN 61000-4-11 100%U, 70%U, 40%U,

Table 2 EMC Immunity

Table 1 EMC Emission

AC semiconductor motor controllers and conductors for non-motor

loads

EN 60947-4-3

Emission enclosure

compliant in ring mode single cycle and phase angle if external

lter tted

EN 60947-4-3

CISPR-11

EN 55011

Class A Group 2

Safety requirements for electrical equipment for measurement,

control and laboratory use

EN 61010-1

UL 508

Table 3 LVD Safety

ATTENTION

This product has been designed for class A equipment. Use of the product in domestic environments may cause radio

interference, in which case the user may be required to employ additional mitigation methods.

EMC filters are required in PA mode (Phase Angle, i.e., SCR trigger with phase angle modulation).

The filter model and current level depend on the configuration and load used.

The power filter MUST by connected as close as possible to the GTF.

You can use a filter connected between the power line and GTF or an LC group connected between the GTF output and the load.

680960_MHW_GTF_01-2012_ENG

INSULATION DIAGRAM

POWER SUPPLY

18...32Vdc

LEDs

OUTPUTSCPUINPUTS POWER CONTROL

MAIN INPUT IN1

DIGITAL INPUT

INPUT TA

Main Processor LOGIC

EEprom

RAM

Connected to 7.5V

CPU

Connected to

18...32Vdc

Connected to

5V (PORT 1)

Connected to

90...600V

Legend

1KV

7.5V

1KV DC / DC

4KV

max 600Vac

SSR

OUT HB

1KV

MODBus RS485

80960_MHW_GTF_01-2012_ENG

2.4 Dimensions

Fastening may be done on DIN guide (EN50022) or with (5MA). See figures 1 and 2.

All dimensions are expressed in mm.

2.4.1 TEMPLATE DIMENSIONS

Figure 1

Figure 2

Models option Fuse = 0

GTF 75 (Without Fan)

GTF 90 (Without Fan)

GTF 120 (With Fan)

Depth 143 mm Depth 143 mm Depth 143 mm

Depth 157.5 mm

Fan

Models option Fuse = 2 El Fuse

GTF 25 (Without Fan)

GTF 40 (With Fan)

GTF 50 (With Fan) GTF 60 (With Fan)

Fan

L (mm) W(mm)

Models NO Fuse

GTF 25-40-50-60A: 112 44

GTF 75-90-120A: 112 113

GTF 150-2000-250A 287 42

Models El. Fuse

GTF 25-40-50A: 112 44

GTF 60A: 112 113

GTF50 (Without Fan)

GTF60 (Without Fan)

GTF 25

GTF 40

880960_MHW_GTF_01-2012_ENG

Figure 3

2.5 installation

Attention: respect the minimum distances shown in figure 3 to provide adequate air circulation.

For correct attachment/release of the module on the DIN guide, do as follows:

- keep the attach/release cursor pressed

- insert/remove the module

- release the cursor

PHASE ATTACHMENT PHASE RELEASE

GTF

locked properly

to DIN bar

TURN

PRESS PRESS

Figure 4 Figure 5 Figure 6

80960_MHW_GTF_01-2012_ENG

Input connector

Cooling Fan

TTL port for

conguration by PC

“Load”

terminal

RJ10

connector

serial RS485

Dip Switch

serial line

Line voltage

connector

Internal fuse

protection

cover

Figure 7

Figure 8

2.6 General DescriPtion GTF 25-120A

2.7 General DescriPtion Gtf 150-250a

HB Key

calibration

Conguration

TTL port

Indicator

LEDs

RS485

Serial port

connector

Switch

serial terminal

Address

Rotary-switch

Supply/Control

connector

Power

terminal

GTF Standard GTF with RS485 option

Heatsink

Attachment

DIN bar

“Line”

Terminal

LED

indicators

HB Key

calibration

Control input

connector

Output

connector

Address

Rotary-Switch

Supply

connector

GTF 150-250A Standard GTF 150-250A

with serial option

10 80960_MHW_GTF_01-2012_ENG

2.8 cleaninG/checkinG or rePlacinG the fan GTF 150-250a

1. Fan

2. Lower grille

(ventilation intake)

3. Detail of insertion of

fan connector in PCB

Figure 9

PERIODIC CLEANING

Every 6-12 months (depending on the dust level of the installation) blow a compressed air jet downward through the

upper rectangular cooling grilles (on the side opposite the fan).

This will clean the internal heat dissipater and the cooling fan.

IN CASE OF OVERHEAT ALARM

If periodic cleaning does not eliminate the problem, do as follows:

aRemove the fan support grille by detaching the two support tabs

bDisconnect the fan connector from the board

cCheck the condition of the fan

dClean or replace the fan

Attention: check that the arrow (on the fan indicating the direction of air flow is pointing to the heat sink

eInsert the connector into the board

fInsert the fan support grille until it attaches

gPower up the device and check fan rotation when at least one load is on

80960_MHW_GTF_01-2012_ENG

Figure 10

2.9 rePlacinG the internal fuse (oPtional only for Gtf 150-250a)

CUT OFF POWER BEFORE AND DURING FUSE SUBSTITUTION PROCEDURE

- Undo the cover fastening screw (1)

- Remove the cover following the movement indicated by the arrow (2)

- In this way the fuse is discovered (3)

- Loosen the two fastening nuts of fuse by means of fixed spanner N.13 (GTF 150)

- It is not necessary to remove the nuts as the fuse N.17 (GTF 200-250A) is slipped off its seat by turning it (1) and

extracting it (2) as indicated by the arrows

- Insert the new fuse as indicated by the arrows (1,2)

WARNING: the washer must remain between the dice and the fuse (NOT under the fuse).

- Fasten the two nuts by the 3-4 Nm

torque tube-shaped spanner N. 16

- Replace the cover pointing it to

the lower part (pay attention to the

connection tooth)

- Fasten the cover by the specific

screw

12 80960_MHW_GTF_01-2012_ENG

3.1 Power connections

RECOMMENDED WIRE GAUGES

RECOMMENDED CABLE SIZES

3 • ELECTRICAL CONNECTIONS

Table 4

Table 5

GTF CURRENT LEVEL TERMINAL CABLE WIRE WIRE TERMINAL TIGHTENING TORQUE /

TOOL

25A 1/L1, 2/T1, PE 4 mm² Wire terminal / Eye

D. 6mm