Gefran GTF Xtra Series Power Controller Manual PDF
Contents
1. KeyHB 7 2 3 45 6 7 8 9 Ji Power supply control connector i __ Fixing screw GERRAN at heatsink Green Led RUN Yellow Led STATUS PO eun ___ Identification label PSO status Red Led Alarm output HB O OuT aL O is Yellow Led Status digital input DO ON OVER T Led Green ThyristorON __ __ Fixing screw Yellow Temperature OVER at heatsink 1 L1 2 T1 LINE connection LOAD connection 3 L2 Reference connection of line voltage EARTH 80994 MHW GTF Ktra 10 2013 ENG 11 34 FUNCTIONS OF INDICATOR LEDS Description of LEDs Table 5 LED DESCRIPTION COLOR Flashing during normal operation RUN green On steadily according to FW setting see SW manual Off during normal operation STATUS yellow On according to FW setting see SW manual ALARM State HB alarm output Power Fault Alarm Fuse Open red DI State digital input yellow Green SSR on control state green ON OVER TEMP Yellow ON SSR overtemperature alarm yellow The state of the LEDs matches the corresponding parameter except in the following special cases S LED 1 green LED 2 yellow both flashing rapidly autobaud in progress LED 2 yellow flashing rapidly SSR temperature sensor broken or SSR Over Heat or Rotation Error or Load_short_protection 3 5 CONTROL CONNECTOR 3 5 1 CONNECTOR J1 Figure 9 G2. Example of conduction angle limitation in PA mode to respect an RMS current limit below the nominal current of the load 80994_MHW_GTF Xtra_10 2013_ENG 19 DT Delay triggering for ZC BF control modes only Settable from 0 to 90 Useful for inductive loads transformer primaries to prevent current peak that in certain cases could trip the high speed fuses that protect the SCRs Figure 24 Transient with Transient without Over Current Over Current Example of firing of inductive load with without delay triggering To conduct inductive loads controlled in PA mode do not use delay triggering instead use the phase Soft Start ramp Figure 25 YA ya lt gt gt lt Example of phase ramp to fire a Example of firing with Delay transformer in PA mode Triggering of a transformer in ZC mode Comparison of method to fire a transformer Soft Start Ramp for PA mode Delay triggering for ZC and BF mode 20 80994_MHW_GTF Xtra_10 2013_ENG 3 10 OVERCURRENT FAULT PROTECTION This function eliminates the need for an external extra rapid fuse to protect the device The SHORT CIRCUIT S CURRENT alarm trips when the peak current on the load exceeds maximum permitted value corresponding to twice the rating during the softstart ramp or at first power on with softstart ramp disabled If configured Fr n parameter other than zero the device restarts automatically in softstar
3. RS485 MODBUS RJ10 Cable PLC HMI gt GTF with RS485 NOTE The standard products DO NOT feature the comunication RS485 Modbus serial port but can be configured via PC with Gefran GF Express Software by connecting it to TTL port of GTF to PC by means of TTL cable equipped with SW Gefran Adapter TL cable R WA RS232 or F049095 Mai aire standard USB F043956 or NEVER connect TTL connector or GTF to a RS485 serial web i NEVER connect TTL adaptator to RS485 serial port of GTF Danger of product damage 80994_MHW_GTF Xtra_10 2013_ENG 23 4 1 AUTOBAUD SERIAL 1 seguence Function Adapt the serial communication speed and parity of the GTF modules to the connected supervision terminal or PLC The RUN and STATUS LEDs mentioned in the Re procedure can vary its behavior based on on he parameters Ld 1 e Ld 2 Procedure 1 Connect the serial cables for all modules on the network t and to the supervision terminal 2 Set the rotary switch on the GTF modules to be installed or on all modules present in case of first installation to position 0 0 3 Check that the RUN and STATUS LEDs flash at high frequency 10Hz 4 The supervision terminal must transmit a series of generic MODBUS read messages to the network 5 The procedure is over when all of the RUN and STATUS LEDs on the GTF modules flash at a normal fr
4. FUSE GG FUSE GG L1 L2 N GTF STATUS MASTER FIRING MODE ZC BF HSC PA HB DIAGNOSTIC AVAILABLE EARTH partial and total load failure FUSE GG see Fuse section Connection example GTF for 1 single phase load with transformer single phase line L1 N or open delta L1 L2 Figure 13 Analog Output 4 0 20 mA eas ee ka ia ania Se 4 20 mA i bamda 0 10 V HB OUT ___ i POTENTIOMETER 0 5 v ALARM SWITCH rth 123456789 24 Vde ac SUPPLY 8 GTF 8 REGULATOR Load FUSE GG FUSE GG hh L2 N GTF STATUS MASTER FIRING MODE ZC BF PA HB DIAGNOSTIC AVAILABLE EARTH partial and total load failure FUSE GG see Fuse section 14 80994 MHW GTF Ktra 10 2013 ENG Connection ekample 2 phase Master Slave GTF for one load 3 phase Figure 14 HB OUT ALARM SWITCH EARTH Phase R Phase S Phase T FUSE _ GG Analog Output mA pa T Men WA POTENTIOMETER FUSE GG FUSE GG GTF 1 STATUS MASTER GTF 2 STATUS SLAVE BI PHASE FIRING MODE ZC BF HB DIAGNOSTIC AVAILABLE total load failure of each single leg partial only for closed trian
5. Eye 2 2 5 Nm Phillips screwdriver 10 mm Wire terminal Eye 2 2 5 Nm Phillips screwdriver 16 mm Wire terminal Eye 2 2 5 Nm Phillips screwdriver 0 25 2 5 mm i 3 L2 Ref Vline wire terminal tip 0 5 0 6 Nm Screwdriver blade 23 14 AWG 0 6 x 3 5 mm 10 mm Wire terminal Eye 2 2 5 Nm Phillips screwdriver 10 80994 MHW GTF Ktra 10 2013 ENG 3 2 CONNECTIONS INPUT OUTPUT GTF 25 120A Figure 8 Top view WITHOUT option Fieldbus Key HB J2 TTL port for PC configuration Master Slave connection Alarm output Syncronous output for solid state relay HB option i RJ10 connectors RS485 serial line Top view WITH option Fieldbus Key HB Address x 1 J3 J4 Address x 10 Switch for serial line Modbus GND Input control signal Potentiometer output power supply 5Vdc Digital input PWM input T Power supply terminal 24Vac Vdc
6. Q Table 6 o gi Q 24 14AWG OO Q Q 0 25 2 5mm 23 14AWG TATATATA eUUeU Ub ey O CON Ook WN Figure 10 Connection schema J1 OUT HB ae y Table 7 PIN NAME DECRIPTION mat OUT MASTER OUT TO GTF SLAVE 4 GND 1 eee GND 5 OUT AL HB OUT Alarm Switch HB mA v sige ee ee ee to IN 3 OUT Master Control output Slave 7V l 7 Sana 4 GND GND Control analog input Petes ae Sai 5 IN Control analog input DI ee eed i i D 6 5V_POT Output alim potentiometer SUPPLY 7 IN_DIG Digital input amp PWM Input ese rcs 8 24V Suppl a Poy Supply 18 32 Vac Vde 9 24V Supply 12 80994 MHW GTF Ktra 10 2013 ENG 3 6 CONFIGURATION TTL Port GTF STANDARD CONNECTOR J2 GTF Connector S1 S2 D ti RJ10 4 4 pin escription Ground O se Data reception TTL from a ee _ The use of this port is recommended TX_TTL Data transmission TTL to GTF to configure parameters by Accessory Reserved Gefran DO NOT connect Gefran cable code F049095 USB TTL or Gefran cable code F043956 a Cable type flat telephone cable for pin 4 4 conductor 28AWG 3 7 SERIAL COMMUNICATION PORTS MODBUS RS485 Option CONNECTORS J3 J4 GTF C
7. wod33 lt LNdNI 7V LIDIG lt 21907 lt Josse00lq UIEN lt i LNI LNANI NIVA Aye i SLNdLNO nda SINdNI TOHINOJ YAMOd 80994 MHW GTF Ktra 10 2013 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 Figure 1 GTF 25 without fan GTF 40 with fan GTF 50 with fan GTF 60 with fan 100 A A HA m Fan k y ji Overvoltage protector Depht 143 mm Depht 143 mm Fastening may be done on DIN guide EN50022 or with 5MA All dimensions are expressed in mm 2 4 1 TEMPLATE DIMENSIONS Figure 2 L mm W mm L GTF 25 40 50A 112 44 GTF 60A 112 113 Models 80994_MHW_GTF Xtra_10 2013_ENG 2 5 INSTALLATION A Attention respect the minimum distances shown in figure 3 to provide adeguate air circulation Figure 3 gt 20 mm 7 amp D 5 yA z E O O yA For correct attachment release of the module on the DIN guide do as follows keep the attach release cursor pressed insert remove the mod
8. GTF 40 50A 1 1 Kg GTF 60A 1 5 Kg 5 1 DERATING CURVES Figure 27 80994_MHW_GTF Xtra_10 2013_ENG 27 6 TECHNICAL COMMERCIAL INFORMATION This section contains information on order codes for immediately identifies the unit s hardware configuration the Controller and its main accessories Therefore you must always give the order code when contacting Gefran Customer Care for the solution to any As mentioned in the Preliminary Instructions in this problems User Manual a correct reading of the Controller order code FIELDBUS MODBUS RTU CONTROL OPTIONS Absent NOMINAL CURRENT 2 E E Note All models have 480VAC nominal voltage and are equipped with a partial total load interrupt HB function Current limit and feedback V I P Signal control configurable Note 10V Default Configurator Standard 1 B M if not differently 5V Potentiometer specified Substitution model PWMDigital input GTS GTF X 480 0 0 0 0 5 Z S GTT without load interrupted option GTF X 480 0 0 0 0 1 B M rom e PA E GTT with load interrupted option GTF X 480 0 1 0 0 1 B M Maser eren m 28 80994 MHW GTF Ktra 10 2013 ENG 6 1 Accessories CONFIGURATION KIT KIT PC USB RS485 o TTL j GFe ores 6 2 Fuse GG kit for PC via the USB port Windows environment for GTF standard configuration TTL port for configuration of GTF with t
9. ji f t T 0 10 V ee OES Aa 0 5 V t t mo A POTENTIOMETER by 1 1 Hh P ya TUPIA 23456789 eS G7 BS 24 Vde ac a SUPPLY ta CTF z GTF a GTF i 8 8 8 S 3 3 2 9 REGULATO pi We al 4 a T te r d i 4 1 1 2 7 X o PE Baas i Wu he Sak s1 s 3 FUSE GG FUSE GG JI FUSE GG li FUSE GG MW WWF EARTH Phase R Phase S Phase T a ee ee E GTF 1 STATUS MASTER GTF 2 STATUS MASTER GTF 3 STATUS MASTER FIRING MODE ZC BF HSC PA FUSE GG see Fuse section FUSE GG S1 2 S3 are useful in order to select the maximun power needed and balance the three phase line optimizing the power factor HB DIAGNOSTIC AVAILABLE total and partial load failure Connection example GTF with N 3 GTF for 3 phase star load with neutral Figure 17 HB OUT ALARM SWITCH t t Analog Output 4 T 0 20 mA a E Tii 20 mA pi jag to 4 010V i POTENTIOMETER nla hili mil 123456789 123456789 T2324 567 89 24 Vde Jac SUPPLY g GTF E GTF 8 GIF 3 3 3 2 3 1 REGULATOR Co Ch Star With Neutral Load
10. the current is restored to pre vent system damage in the event that the fault is not effectively cleared The GTF Xtra controller is compact modular and optimised to control virtually any type of restive heating system in a wide range of industrial applications Impressive functionality is assured by a comprehensive array of options that are configurable with intuitive guided set up PC based Windows software GTF Xtra always provides an RS485 serial connection with Modbus RTU protocol to control currents voltages powers load status and device status from the supervisor terminal HMI or PLC 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 SSR 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 This exclusive function is a resettable internal protection against overcurrents it eliminates the external always problematic use of high speed fuses and greatly reduces the length and cost of machine downtime caused by a search for new fuses Device parameters can be configured from PC by means of a sim ple
11. 7 mA State 0 read safe voltage lt 2V State 1 read safe voltage PWM input Measures voltage and line current gt 5V Maximum frequency 0 03Hz 100 Hz maximum resolution 1 0 1ms Function measures the load current Measures RMS voltage by integral calculation of sampled values Meas range 0 2 rated_product Accuracy RMS current measurement 3 Yo f s at room temperature of 25 C In PA mode with conduction angle gt 90 5 fs Thermal drift lt 200 ppm C RMS line current measurement function RMS voltage meas by integral calculation of sampled values Work voltage range 90 480Vac Accuracy RMS voltage measurement 1 Yo f s at room temperature of 25 C Thermal drift lt 100 ppm C Sampling time current voltage 0 25 ms Line frequency 50 60 Hz OUTPUTS CONTROL OUTPUT MASTER SLAVE Function Control for synchronising another GTF or GTS slave 4 slave max Voltage 7 5V max 25 mA HB ALARM OUTPUT Function HB alarm output or of other configurable alarms Type Solid state relay MOS opto Isolated contact normally open Imax 150mA Vmax 30 Vac Vdc Closing resistance lt 15 ohm RS485 Modbus Optional COMMUNICATIONS PORTS Function Local serial communication Protocol ModBus RTU Baudrate Settable 1200 19200 bit s default 19 2Kbit s Node address Settable with two rotary switches rot
12. FUSE GG FUSE GG EARTH Neutral Phase R Phase S Phase T GTF 1 STATUS MASTER GIF 2 STATUS SLAVE GTF 3 STATUS SLAVE FIRING MODE ZC BF HB DIAGNOSTIC AVAILABLE total and partial load failure of each single leg FUSE GG see Fuse section 16 80994_MHW_GTF Xtra_10 2013_ENG A NOTES USE WITH INDUCTIVE LOADS AND TRANSFORMERS 2 Connect a varistor MOV between each wire of the primary transformer and ground Varistor data rated voltage 660Vrms 1000Vrms minimum energy 100J The maximum current controllable by the device is less than the product s rated value see technical data In ZC and BF trigger mode use the Delay triggering function to limit peak magnetization current In PA trigger mode use the Softstart function DO NOT use HSC trigger mode DO NOT connect RC snubbers in parallel to the transformer primary Select the inductive load using the Hd 1 parameter ref Software manual CO ENG Trigger modes The GTF has the following power control modes modulation via variation of number of conduction cycles with zero crossing trigger modulation via variation of phase angle Zero Crossing mode This function eliminates EMC noise This mode controls power on the load via a series of conduction ON and non conduction OFF cycles ZC constant cycle time Tc 1 sec settable from 1 to 200 sec Cycle time is divided into a series of conduction
13. GEFRAN GTF Ktra POWER CONTROLLER WITH OVERCURRENT FAULT PROTECTION INSTALLATION AND OPERATION MANUAL code 80994 10 2013 ENG C INDEX 1 Preliminary instructions 2 3 7 Connection example comunication ports 1 1 Profile 3 8 Connection example power section 1 2 General description 3 9 Option electronic fuse 1 3 Preliminary instructions 3 10 Digital input PWM 2 Installation and Connection 4 4 Installation of serial network 23 2 1 Electrical power supply 4 1 AUTOBAUD SERIAL sequence 2 2 Notes on electrical safety and ji SRA electromagnetic compatibility 5 Technical Characteristics 25 2 3 Recommendations for correct installation for 5 1 Derating Curves purposes of EMC 6 Technical Commercial information 28 2 4 Dimensions 2 5 Installation 2 6 General description GTF 25 60A 6 1 Accessories 6 2 Fuses Fuseholders 3 Electrical connections 10 3 1 Power connections 3 2 Connections input output 25 120A 3 3 Functions of indicator leds 3 4 Control connectors 3 5 Configuration TTL port GTF standars 3 6 Serial comunication port Modbus RS485 option 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 Indicates a suggestion based on the experience of GEFRAN s Technical Personnel that could be IZ Indicates contents of sections general instructions notes and
14. an air conditioner to tran sfer dissipated power outside the panel presence of dispersion current in GTF in non conducting state current of a few mA due to RC Snubber circuit to protect GEFRAN S p A assumes no liability for any da mage to persons or property deriving from tam RS pering from incorrect or improper use or from any use not conforming to the characteristics of the controller and to the instructions in this User maximum limits of voltage and derived power of transients on Manual the line for which the solid state power unit contains protective devices based on the model Table 1 EMC Emission AC semiconductor motor controllers and conductors for non motor EN 60947 4 3 loads Emission enclosure EN 60947 4 3 Class A Group 2 compliant in firing mode single cycle and phase angle if external CISPR 11 filter fitted EN 55011 Table 2 EMC Immunity 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 eart
15. and non conduction cycles in proportion to the power value to be transferred to the load Figure 18 For example if Tc 10sec if the power value is 20 there is conduction for 2 sec 100 conduction cycles 50Hz and non conduction for 8 sec 400 non conduction cycles 50Hz BF variable cycle time GTT This mode controls power on the load via a series of conduction ON and non conduction OFF cycles The ratio of the number of ON cycles to OFF cycles is proportional to the power value to be supplied to the load The CT repeat period is kept to a minimum for each power value whereas in ZC mode the period is always fixed and not optimized 80994_MHW_GTF Xtra_10 2013_ENG 17 Figure 19 au parameter defines the minimum number of conduction cycles settable from 1 to 10 In the following ekample the parameter 2 HSC Half single cycle This mode corresponds to Burst Firing that manages ON and OFF half cycles It is useful for reducing the flickering of filaments with short medium wave IR lamp loads With these loads to limit operating current with low power it is useful to set a minimum power limit for example Lo p 10 NB This mode is NOT allowed with inductive loads transformers It is used with resistive loads in single phase star with neutral or open delta configuration Figure 20 Example of operation in HSC mode with power at 33 and 66 Phas
16. ary switches Type RS485 double connector RJ10 telephone type 4 4 Isolation 500V TTL serial connector Standard Function For product initial configuration only via PC Use a PC connected to GTF ONLY via Gefran adapter Code F049095 PC with USB or Code F043957 PC with RS232 Isolation TTL serial NOT isolated of CPU 80994 MHW GTF Ktra 10 2013 ENG POWER SOLID STATE CATEGORY OF USE AC 51 resistive or low inductance loads Tab 2 EN60947 4 3 AC 55b short wave infrared lamp SWIR AC 56a transformers Reguest application check Trigger mode PA Load management by adjusting the firing angle only configuration single phase or delta open ZC Zero Crossing with constant cycle time settable in range 1 200sec BF Burst Firing with variable cycle time GTT optimized minimum HSC Half Single Cycle corresponds to Burst Firing that includes ON and OFF half cycles Useful for reducing flicker with short wave IR loads applied only to single phase resistive or 3 phase 6 wire open delta loads Feedback mode V V2 Voltage feedback proportional to RMS voltage value on load useful to compensate possible variations in line voltage I 12 Current feedback bound to RMS current value on load to compensate variations in line voltage and or variations in load impedance P Power feedback proportional to real power value on load useful to keep constant values of electrical power assi
17. ation 5 x M or must be configured with the parameter dIG digital input 7 see Fig 46 47 Figure 26 Logic output D type HB OUT ALARM SWITCH pine 123456789 aeons 600 24 Vde ac SUPPLY i GTF 6056 8 REGULATOR 22 80994 MHW GTF Ktra 10 2013 ENG 4 INSTALLATION OF THE SERIAL PORT A network typically has a Master that manages communication by means of commands and Slaves that carry out these commands GTF modules are considered Slaves to the network master which is usually a supervision terminal or a PLC It is positively identified by means of a node address ID set on rotary switches tens units A maximum of 99 GTF modules can be installed in a serial network with node address selectable from 01 to 99 GTF modules have a ModBus serial Optional The MODBUS RTU port 1 has the following factory settings default Parameter Default Range ID 1 1 99 BaudRate 19 2Kbit s 1200 19200bit s Parity None Odd Even None StopBits 1 DataBits 8 The following procedures are indispensable for the Modbus protocol Set the rotary switch at 0 0 for AutoBaud function Position Parameter rotary switches tens unit AutoBaud 0 0 Allows setting of the correct BaudRate value automatically detecting the master transmission frequency
18. configuration SW which lets you save all parameters in a con figuration file 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 IEY 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 e Metal heat treating furnaces e Vacuum furnaces with graphite elements High temperature furnaces Boosters for glass lines Quick cutting on blow molding lines e Machines and lines with unwanted current peaks and arcs e Fuse free solutions 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
19. e angle PA This mode controls power on the load via modulation of trigger angle 0 Example if power to be transferred to the load is 100 9 180 or _ if power to be transferred to the load is 50 0 90 Figure 21 Ve Resistive load Inductive load 18 80994_MHW_GTF Xtra_10 2013_ENG ADDITIONAL FUNCTIONS Softstart This type of start can be enabled either in phase control or pulse train mode and in zero crossing mode ZC BF HSC In phase control the increment of conduction angle q stops at the corresponding value of the power to be transferred to the load Control of maximum peak current useful in case of short circuit on the load or of loads with high temperature coefficients to automatically adjust start time to the load can be enabled during softstart When the load shut off time settable is exceeded the ramp is reactivated at the next power on Figure 22 Example of firing ramp with phase Soft Start RMS current limit The option for controlling the load current limit is available in all work modes If the current value exceeds the limit settable in the nominal full scale range in mode PA the conduction angle is limited while in zero crossing mode ZC BF HSC the cycle time conduction percentage is limited This limitation ensures that the RMS value i e not the instantaneous value of the load current does NOT exceed the set RMS current limit Figure 23
20. ect Opening energy Depending on model Depending on model e Always very low l t of opening e Low medium high e Medium high Openino time Depending on model Depending on model e Always very low micro seconds pening Low medium high Medium high e Replacement e Manual reset e Manual reset e Labour cost fuse Automatic reset FR n times change e Remote reset via serial 80994_MHW_GTF Xtra_10 2013_ENG 21 3 11 DIGITAL INPUT PWM This digital input can be used to receive information on the of power to be supplied to the load The signal can be generated by a controller or external pic via digital outputs logic output for Gefran instrumentation This is obtained by alternating the output in ON for time TON with the output in OFF for time TOFF The sum of TON TOFF is constant and is called CycleTime CycleTime TON TOFF The power level is given by the ratio TON CycleTime and is normally expressed in The GTF digital input automatically adapts to the cycle time from 0 03Hz to 100Hz and obtains the power to be supplied to the load from the TON TON TOFF ratio Connection example Temperature control with Gefran 600 with D type logic output out2 cycle time 0 1sec logic output can drive max 3 GTF in series preferable connection allowed only if GTFs do not have interconnected GNDs if so make parallel connection To use Digital PWM the GTF can be ordered with the configur
21. equency 2Hz if parameter 50 Ld 1 16 as default The new speed parameter is saved permanently in each GTF therefore the AUTOBAUD SERIAL sequence does not have to be run at subsequent power ups Oo When the rotary switch is turned the green STATUS LED stays on steadily for about 6 seconds after which it resumes normal operation and saves the address INSTALLATION OF SERIAL NETWORK 1 ModBus Bers oe os l The serial network communication speed is the same as for GTF AUTOBAUD SERIAL 1 SEQUENCE RUN and STATUS LEDs flashes at 10 Hz SETTING THE NODE ADDRESS OPERATIVE FUNCTION 24 80994 MHW GTF Ktra 10 2013 ENG 5 gt TECHNICAL CHARACTERISTICS INPUTS IN1 Analogic control inputs Function Acquisition of control power Max error 1 f s 1 scale point at ambient temperature of 25 C Thermal drift lt 100 ppm C of f s Sampling time 60 ms Scale 0 10V Input impedance gt 40 Kohms Scale 0 5V Input impedance gt 40 Kohms Scale 0 20mA or 4 20mA Internal Shunt resistance 125 ohm Potentiometer input Potentiometer resistance from 1 Kohm to 47 Kohm Potentiometer supply 5V supplied by GTF max 10mA Linear input read scale 0 100 0 Yo INDIG Digital Input Function Power Disable input or PWM input Voltage range 5 30V max
22. especially useful under certain circumstances other points to which the reader s attention needs to be called the safety or correct operation of the controller or an Documents available on the GEFRAN website instruction that MUST be followed to prevent hazards www gefran com Indicates a particularly delicate situation that could affect A Indicates a reference to Detailed Technical A Indicates a risk to the user s safety due to high voltage at the points indicated 80994 MHW GTF Ktra 10 2013 ENG 1 1 PRELIMINARY INSTUCTIONS 1 1 PROFILE The Gefran GTF Xtra power controller combines the functiona lity of a single two or three phase solid state power unit and controller with the benefits of the unique integrated overcurrent fault protection function The fault protection eliminates the need for extra rapid fuses reducing machine downtime and the cost of replacing fuse fai lures It does so by instantaneously monitoring load current cutting the power if the load reaches a pre set threshold and isolating the power switching devices In applications susceptible to intermittent short circuits and overloads the Gefran Xtra power controller can be program med to restore power automatically when the fault has cleared preventing complete process shutdown and maintaining pro duction Alternatively power can be manually restored locally or remo tely A soft start ramp is applied when
23. for the instrument part e Electronic instrumentation and electromechanical power a CAREFULLY READ THE FOLLOWING WARNINGS devices such as relays contactors solenoids etc MUST BEFORE INSTALLING THE INSTRUMENT ALWAYS be powered by separate lines Disregard of such warnings could create When the power supply line of electronic instruments is electrical safety and electromagnetic heavily disturbed by switching of thyristor power groups or compatibility problems as well as void the by motors you should use an isolation transformer only for warranty the controllers grounding its sheathing It is important for the system to be well grounded 2 1 ELECTRICAL POWER SUPPLY voltage between neutral and ground must not be gt 1V Ohmic resistance must be lt 6Q the controller DOES NOT have an On Off switch the user Ifthe grid voltage is highly unstable use a voltage stabilizer must install switch isolator conforming to safety requisites CE In proximity of high frequency generators or arc welders mark to cut off the power supply up line of the controller use adequate grid filters The switch must be installed in the immediate vicinity of the The power supply lines must be separate from instrument controller in easy reach of the operator input and output lines A single switch can be used for multiple devices A Supply from Class II or from limited energy source the earth connection must be made with a specific lead if the p
24. gle see Fuse section i 24 Vde ac SUPPLY Closed Delta Load 0 20 REGULATOR Star Load FUSE GG Connection example 3 phase Master Slave with control on 3 lines GTF for one load 3 phase Figure 15 HB OUT ALARM SWITCH T t f Analog Output 4 T 0 20 mA PAAIE MIAK SEA NA il r ear t mmi POTENTIOMETER 1 1 1 l za 123456789 123456789 125456789 24 Vde ac SUPPLY 8 GTF 9 GTF 9 GTF 3 5 2 1 REGULATOR 1 L1 2 1 1 L1 2 11 em O SAR G 3 12 3 12 8 9 TE TE TE i Closed Delta Star Load Load FUSE GG Ii FUSE GG FUSE GG ll me Phase S Phase T GTF 1 STATUS MASTER HB DIAGNOSTIC AVAILABLE GIF 2 STATUS SLAVE BI PHASE total and partial load failure aie asa ales SLANE FUSE GG see Fuse section FIRING MODE ZC BF 80994_MHW_GTF Xtra_10 2013_ENG 15 Connection ekample GTF three phase 3 master units for single phase loads with division of makimum load with isolators S1 S2 S3 maintaining balance of three phase line Figure 16 HB OUT ALARM SWITCH t t t Analog Output
25. gned regardless of load impedance or line voltage variations Max rated voltage 480Vac Work voltage range 90 530Vac Non repetitive voltage 1200Vp Rated frequency 50 60Hz auto determination MODEL GTF Rated current AC51 AC55b non inductive or slightly i 60 inductive loads IR lamps Tamb 40 C 25 0 50 25A 40A 50A 60A Rated current AC56A permitted trigger modes ZC BF con DT Delay Triggering PA with softstart Tamb 20A 32A 40A 50A 40 C Overcurrent Fault Protection function This option eliminates the need for an external extra rapid fuse to protect the device In case of load short circuit the internal IGBT device is instantaneously switched off and the alarm status is signaled Critical Dv dt with output deactivated 1000V usec Held nominal voltage of on the impulse 4KV Breaking 5KA 480V FUNCTION Diagnostics Detection of short load circuit absence line voltage HB alarm partial breakage of load OPTIONS Options Timed Soft Start firing ramp with or without peak current control Soft Start firing ramp specific for infrared lamps Timed shut off ramp Limitation of RMS current in load 0 90 Delay Triggering for firing inductive loads in ZC and BF mode Diagnostic SSR in short circuit presence of current with OFF control Absence of SSR current when under load Overtemperature alarm Current read HB alarm interrupted or partially inte
26. h 2 kV Signal line line 1 kV Magnetic fields 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 3 LVD Safety Safety requirements for electrical equipment for measurement control and laboratory use EN 61010 1 UL 508 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 SSR 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 The CE declaration of conformity is available on request 80994_MHW_GTF Xtra_10 2013_ENG INSULATION DIAGRAM A08r 06 0 pajoguU09 PAZE Sh 0 peyoauu0D NdO AG Z 0 payoauu0g puabaj OPAZE BL cersusnagon ne AGL nee ren ere EE S A AML AML AlddNS YIMOd SG ee nn ne gH LNO H i i i lt WH lt VL LNdNI AML lt
27. he RS485 option Lets you read or write all of the parameters of a single GTF Asingle software for all models Easy and rapid configuration Saving and management of parameter recipes On line trend and saving of historical data Component Kit Connection cable PC USB lt gt GTF port TTL Connection cable PC USB lt gt GTF RS485 port Serial line converter CD SW GF Express installation ORDERING CODE GF_ XK 2 0 0 00 eet Cod F049095 The electric protection device called FUSE GG must be done in order to grant the protection against the electric cable short cirrcuit see EN60439 1 par 7 5 Short circuit protection and short circuit with stand strength and 7 6 Switching devices and components installed in assemblies otherwise the equivalent EN61439 1 paragraphs 80994 MHW GTF Ktra 10 2013 ENG 29
28. of programming and configuration parameters are contained in the Programming and configuration manual IE downloadable from the website www gefran com 80994 MHW GTF Ktra 10 2013 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 I 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 SN oianak Serial number CODE irasi ariannin Product code UPE Order code SUPPLY iiciin Power Supply VERS ceee Firmware version 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 60 480 0 1 0 M Model Nominal current Nominal voltage Control option Absent Diagno
29. onnector S1 S2 D ti RJ10 4 4 pin escription on omo EER a reception transmission C Insert the RS485 line termination in the last device on the Modbus line C e a Connect the GND signal between Modbus devices with a line distance gt 100 m Cable type flat telephone cable for pin 4 4 conductor 28AWG 3 8 CONNECTION EXAMPLE COMMUNICATION PORTS Integration of GTF with GEFLEX modules connected in R8485 Modbus Figure 11 mene pordcad canon NA a E e Z n i elelelall g ER 0 E Flat HE RS485 A r 80994_MHW_GTF Xtra_10 2013_ENG 13 3 9 CONNECTION EXAMPLE POWER SECTION Connection example GTF for 1 single phase load single phase line L1 N or open delta L1 L2 Figure 12 Analog Output 0 20 mA 4 20 mA HB OUT POTENTIOMETER ALARM SWITCH ilti 124456789 24 Vde fac SUPPLY hasa REGULATOR caooo LOAD
30. panels or control panels of production y automatic switch to arn ae power aR i process machines or systems o ensure maximum reliability the device must be correctly eT i i i i te heat For purposes of electromagnetic compatibility the most installed in the panel in such a way as to obtain adequate hea i dards h b dopted h exchange between the heat sink and the surrounding air under restrictive generic standards have been adopted as shown conditions ofnaturalconve tion on the table Fit the device vertically maximum angle 10 to the vertical axis see figure 3 2 2 2 LV low voltage conformity e Vertical distance between a device and the panel wall in compliance with Directive 2006 95 CE gt 100mm e Horizontal distance between a device and the panel wall at i _ last 10mm O EMC compliance has been verified with respect to Vertical distance between a device and the next one at last the information in Tables 1 and 2 300mm e Horizontal distance between a device and the next one at last 10mm 4 80994_MHW_GTF Xtra_10 2013_ENG Check that the cable holder runners do not reduce these di stances in this case fit the cantilever units opposite the panel so that the air can flow vertically on the dissipator without any obstacles e dissipation of device thermic power with effects on installation room temperature e thermal power dissipation with limits on installation room tem perature requires exchange with external air or
31. roduct is used in applications with risk of harm to 2 3 2 Input and output connections persons or damage to machines or materials it MUST be Before connecting or disconnecting any connection always check equipped with auxiliary alarm devices that the power and control cables are isolated from voltage It is advisable to provide the ability to check for tripped alarms Appropriate devices must be provided fuses or automatic during regular operation switches to protect power lines DO NOT install the product in rooms with hazardous The fuses present in the module function solely as a protection inflammable or explosive atmosphere it may be connected for the GTF semiconductors to elements that operated in such atmosphere only by means Connected outside circuits must be doubly isolated of appropriate interfaces that conform to current safety To connect analog inputs strain gauges linears TC RTD standards 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 2 NOTES ON ELECTRICAL SAFETY AND ELECTROMAGNETIC COMPATIBILITY 233 Installation notes 2 2 1 CE MARKING EMC Install the voltage stabilizer enclosed with the product electromagnetic compatibility conformity A see Installation section in compliance with Directive 2004 108 CE and following modifications N use installed on
32. rrupted load Automatic calibration of HB alarm setpoint starting from current value in load Alarm for load in short circuit or overcurrent Voltage read No line voltage GENERAL DATA Power supply GTF 25 60A 24 Vac 50 60 Hz Vdc 25 max 3VA Power supply external fan only for 40 50 60A model Signals 5 leds RUN run state of CPU STATUS operating state ALARM state of alarm output DIGITAL INPUT state of digital inputs ON OVER TEMP state control tirystor Alarm for overheating Load type and connection Single phase load Independent single phase load in open delta 3 phase load 3 phase load star without neutral or closed triangle with bi phase control 24 Vdc 10 max 200mA 26 80994_MHW_GTF Xtra_10 2013_ENG GENERAL DATA Protection IP20 Work storage temperature 0 40 C refer to dissipation curves 20 C 70 C average temperature over a period of 12 0 am not exceeding 35 C according to EN 60947 4 3 7 1 1 Relative humidity 20 85 RH non condensing Ambient conditions for use indoor use altitude up to 2000m Installation DIN bar EN50022 or panel with screws Installation requirements Installation category Il pollution level 2 double isolation only for model gt 120A Max temperature of air surrounding device 40 C for temperature gt 40 C refer at derating curves Device type UL Open Type Weight GTF 25A 0 97 Kg
33. stic 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 e MODBus Protocol CE 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 O Freguently Asked Questions section on the Gefran website www gefran com 80994_MHW_GTF Xtra_10 2013_ENG 2 INSTALLATION AND CONNECTION This section contains the instructions needed for 2 3 RECOMMENDATIONS FOR CORRECT INSTALLATION correct installation of GTF controllers on the FOR PURPOSES OF EMC LZ machine host system control panel and for correct 2 3 1 Instrument power supply connection of the power supply inputs outputs and The power supply for the electronic instrumentation on the interfaces panels must always come directly from a cut off device with fuse
34. t for a maximum number Fr n of attempts beyond which it remains deactivated while waiting for manual reset with front panel key BUT or with the control via serial bit 16 83 Fra R W Number of restarts in case of FUSE_OPEN 16 Reset alarms SHORT_CIRCUIT_CUR RW OFF bit RENT E FUSE_OPEN ON Reset alarms SHORT_CIRCUIT_CURRENT e FUSE_OPEN A DOES NOT replace any of the safeties on the system such as magnetothermic switches delay fuses etc Protects the controller and therefore also the load by replacing the high speed fuse needed to protect the control SCRs against faults without creating any additional cost to replace the fuse and reducing machine downtime Has 2 function states V Normal On Off control of load power V Fuse Open GTF is open a short occurred during normal operation Conditions of use Breaking capacity 5 KA 480V Max system inductance 1000 uH DIFFERENCES AMONG SHORT CIRCUIT PROTECTION DEVICES Characteristics Fuses e Magnetothermics Overcurrent Fault Protection e Metal melting Thermal effect e Current threshold Opening technique Contact withdrawal with Magnetic effect e Device shutdown preloaded spring e Mechanical release e Arc in air sand e Mechanical separation of 2 contacts No arc in air current shuts down Arc quenching Quenching with silica Arc in air with quenching in chamber in silica sand spring eff
35. ule release the cursor Figure 4 Figure 5 Figure 6 GTF PHASE ATTACHMENT locked property PHASE RELEASE to DIN bar PRESS LI oP c l e I Z TURN 80994_MHW_GTF Xtra_10 2013_ENG 2 6 GENERAL DESCRIPTION GTF 25 60A Figure 7 1 ly control GTF Standard GTF with RS485 option ha HB key calibration TTL port for configura tion 4 LED indicators 5 Power terminal Line 1 L1 6 Power terminal Load 2 71 7 Heatsink 8 Attachment DIN bar 9 Switch serial line terminal 10 RS485 serial port connector 11 Address Rotary switch 12 GTF Surge protector WP 80994 MHW GTF Ktra 10 2013 ENG 3 gt ELECTRICAL CONNECTIONS 3 1 POWER CONNECTIONS RECOMMENDED WIRE GAUGES Table 4 GTF CURRENT LEVEL TERMINAL CABLE WIRE WIRE TERMINAL Pinne ig aa 4 mm Wire terminal
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