Main application Main features PROFILE MODELS
GFX-4
4 LOOP MODULAR POWER CONTROLLER
Main features
4 independent loop control unit.
Compact, ready to use, equipped also with
fieldbus interface.
Unit consisting of:
• Controller
• 30, 60, 80kW solid state relay
• Current transformers (one or four)
• Fuses-holder (option)
• 4 universal main inputs
• 4 heat/cool independent PID
• 4 main output internally wired to the SSR
• 4 auxiliary analog inputs (option)
• 4 configurable output (option):
relay / logic / TRIAC / continuous
• 2 configurable relay alarm output
• 2 digital inputs
• Standard digital communication:
Modbus RTU
• Optional Fieldbus communication:
Profibus DP, CANopen, DeviceNet,
Modbus RTU, Ethernet Modbus TCP
• DIN rail or panel mounting
Main application
•
•
•
•
•
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Packaging
Extrusion
Thermoforming
Injection moulding
Textile
Multizone furnaces
PROFILE
GFX4 is a four independent loop
controller, designed to manage electrical
power.
GFX4 is a compact unit bounding
different technological elements like:
• controller
• solid state relay
• current transformers
• fuses-holders (option)
The final result is a cost saving in terms
of space and cabling.
GFX4 consisting of:
• power management unit
• analog and digital inputs,
• analog and digital outputs
• standard digital communication
• integrated solid state relays
• fuses-holder (option)
Geflex controls autonomously the four
loop controllers, furnishing a complete
diagnostics like the loaded current, the
control of the zones, the alarms state.
A specific step by step software tool has
been develop in order to assist the
product configuration based on the
different applications.
Communication with the outside is of
primary importance.
Geflex dialogs with the operator terminals
according to the most popular protocols:
from the simple and efficient Modbus to,
by a second optional fieldbus
communication, the by-now indispensable
Profibus DP, CANopen, DeviceNet,
Modbus RTU, Ethernet Modbus TCP.
The product’s furnished with a standard
configuration, simple and quickly to
modify.
The assignment of different functions to
the outputs is very simple.
MODELS
(see table in order code)
3 different sizes, depending on the
electric power managed, are available.
GFX4 80
Maximum contemporaneous power up to
[email protected]
Each zone could reach up to 19,2 kW.
This limit could be extend to 23,7 kW
using the “smart power management”
(not all the zone contemporaneous).
Nominal current 40A for zone, not
contemporary maximum 57A
GFX4 60
Maximum contemporaneous power up to
[email protected]
Each zone could reach up to 15,3 kW.
Nominal current 32A for zone
Fuse holder could be provide as an
option.
GFX4 30
Maximum contemporaneous power up to
[email protected]
Each zone could reach up to 7,6 kW.
Nominal current 16A for zone
Fuse holder could be provide as an
option.
INPUTS
Outupt 2 state
O3
Outupt 3 state
O4
Outupt 4 state
Process analogue
4 universal process input could accept:
thermocouple, thermoresistance, current
and tension linear.
The type could be choose by software
and no external converting device are
required.
POWER
Digital
2 digital input.
The functionality could be selected within
a wide range including setpoint selection,
MAN/AUTO, alarm memory reset and
many other.
Power is controlled with double SCR in
anti-parallel, zero crossing switching
principle, with configurable proportional
cycle time.
Different load connection are available:
monophase, dualphases, three-phases.
Incorporated CT
From 1 to 4 CT control each zone and
the relative alarm control is start up
(HB..).
Auxiliary analogue (option)
4 further analogue inputs are available,
typically for external current transformer
reading.
By default a different meaning is
applicable.
FUSES (OPTION)
The fuses are orderable on the GFX4
30KW and 60kW model.
Thanks to this, you save time, wiring is
simplified, and dimensions in the panel
are reduced.
PROGRAMMING
OUTPUTS
Output alarms configurable via software.
Heating control
For each zone an heating control
internally connected to power unit is
present, then no further connections
needed between power unit and
controller.
Cooling control (option)
For each zone a cooling control is
present 4 types of outputs are available:
relay, logic, triac, continuous.
A current transformer is furnished with
TRIAC output.
Alarms
Two relay output configurable as
minimum and maximum alarm are
available for each unit.
LEDS
Eight monitoring led are available in order
to provide diagnostic information.
RN
RUN stet of the CPU
ER
Error
DI1
DI1 digital input state
DI2
DI2 digital input state
O1
Outupt 1 state
O2
The Geflex modules can be programmed:
• using GFX-OP
• using Winstrum tool software
• using Industrial PC or PLC.
monitor load and trip the HB alarm in
case of current failure or SSR in short
circuit.
Detection of short circuit or opening of
input probe, open loop alarm (LBA),
interrupted load alarm (HB).
Over temperature alarm
The software can be used to define the
state of alarm outputs or a preset power
level to be supplied in case of broken
probe.
This assures continuity of service in the
individual zone.
Tuning
• Self-tuning:
calculation of PID parameters at system art.
• Auto-tuning continuous: continuous
adjustment of PID
• Autotuning one-shot: output modulation
and event-driven automatic PID
parameters re-calculation
Special functions
• Soft-start: power parcellization timebased
• Software Off: disabling of the control,
outputs are turned off
• Inputs\outputs: direct management of
inputs/outputs, independently from
internal firmware
• Simulation of four independent Geflex
units.
FUNCTIONS
Control
The Geflex control algorithm works with
any type of thermal process.
Different control modes are available:
from a simple ON/OFF control to PID
single or double acting heat/cool (for
cooling, simply indicate the fluid used).
Sophisticated and efficient automatic
tuning algorithms for control parameters
provide precise process control without
the presence of an operator.
Alarms
There are 8 alarm assignable to each
single canal or to all (AND / OR logic)
and configurable as absolute, relative,
direct, reverse, window, latching or not,
inhibit at power-on.
Diagnostics
Geflex assures efficient process
monitoring from a thermal and electrical
point of view, allowing the operator to
foresee breakdowns or malfunctions and
take timely action (for example, in case
the temperature safety limit is exceeded,
broken probe, load fault).
The LBA alarm precisely checks the
control loop, while the on-board current
transformer (one always present, four
available in option) lets you directly
STANDARD DIGITAL
COMMUNICATION
The product is furnished with standard
digital communication [PORT 1] used as
GFX4 connection to a HMI or Industrial
PC.
Also by a dedicated connector (10 pins)
it’s possible to connect the actual range
of Gefllex.
A second standard digital communication
(PORT 2) configurable by most popular
protocol:
CANopen
DeviceNet
Profibus DP
Modbus RTU
Ethernet Modbus TCP
is available as option.
Net address
Assigned by two rotative selectors.
GENERAL DESCRIPTION
3
13
5
4
6
2
12
7
1
11
10
8
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
8
14
DIN rail frontal
power terminal: screws
power terminal
ventilation grid (attention NOT obstruct)
hook/release device back DIN rail
hole for screws
microswitchs of configuration
standard digital communication
rotative selector switch
connectors J1, J2, J3, J4
fuses-holder (only for 30KW and 60KW models)
fuses-holder terminal (F1, F2, F3, F4)
power terminal (U1, U2, U3, U4)
ventilation grid (attention NOT obstruct)
101,5
92,5
132
140
140
35
4
4
19,5
DIMENSIONS - INSTALLATION
140
109,5
147
42
4
101,5
82
109,5
182
195
140
132
92,5
111,5
147
35
4
19,5
140
DI1, DI2 [digital inputs]
Connector: J2
Function
default not enable (configurable)
Type
PNP, 24Vdc, 8mA (isol. 3500V)
TECHNICAL DATA
OUTPUTS
INPUTS
OUT 1...4 [heating control]
IN1...IN4 [process analog inputs]
Connector: J4
outputs connected to solid state relay
Function
default process variable (configurable)
Sampling time
120msec the four inputs
Accuracy
0,2% FS ±1 steps at 25°C. (16000 points)
Thermal drift
0,005% FS/°C
Type
• Thermocouples ITS90:
J, K, R, S, T, custom (IEC584-1, CEI EN
60584-1, 60584-2).
Internal cold junction compensation with
automatic compensation.
Selectable temperature range: °C/°F
• Thermoresistance: Pt100 DIN 43760
Max. resistance 20Ω
Selectable temperature range: °C/°F
• Voltage: range 0/12...60mV, Ri > 1MΩ
0/0,2…1V, Ri > 1MΩ custom 60mV at 32
sections
• Current: range 0/4...20mA , Ri = 50Ω
custom 20mA at 32 sections
Function
default heating control (configurable)
OUT 5...8 [cooling control]
Connector: J1
Function
default cooling control (configurable)
Type
• Relay: NO, max 3A, 250V/30Vdc,
cosϕ = 1, resistive load
• Logic: 24Vdc, 35mA
• Continuous:
• voltage: 0/2...10V, ±10V, max 25mA
short circuit protection
• current: 0/4...20mA, 500Ω max
• insulation: 3500V
• Triac: 230V/4Amp AC51
(1A for four)
(2A for two)
OUT 9...10 [alarms]
Connector: J1a/J1
IN5...IN8 [auxiliary analogue inputs]
Connector: J3
Function
default alarms (configurable)
Function
default analog inputs reading
Sampling time
480msec for TC, voltage
Accuracy
1% FS ±1 steps at 25°C.
Type
• Thermocouple ITS90:
J, K, R, S, T, custom (IEC584-1, CEI EN
60584-1, 60584-2).
Internal cold junction compensation with
automatic compensation.
• Voltage:
range 0/12...60mV, Ri > 1MΩ
Type
Relay: NO, max 5A, /30Vdc, cosϕ = 1
LEDS
RN
ER
DI1
DI2
O1
O2
O3
O4
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.RUN state of the CPU
.error
.DI1 digital input state
.DI2 digital input state
.Out.1 main input state
.Out.2 main input state
.Out.3 main input state
.Out.4 main input state
IN9...IN12 [internal CT input]
Connector: internal connection
COMMUNICATION PORTS
Function
default internal CT reading
Sampling time
60msec for CT
Accuracy
1% FS ±1 steps at 25°C.
Type
internal CT: 50mAac, 50/60Hz, Ri = 10Ω
PORT 1 [local bus]
Connectors: S1 / S2 / S3
Function: local bus
Protocol: Modbus RTU
Baud Rate: 115Kbps (default)
setting 1200...115Kbps
Node address: setting by double rotative
selector
Connector S1 / S2: 2xRJ114/4, RS485 2
wires insul. 1500V
Connector S3: 10 pins for flat cable
SERIAL 2 [fieldbus]
Connectors: S4 / S5
Function
external fieldbus
Protocol
Modbus RTU _____115Kbps
CANopen ________10K...1Mbps
Profibus DP ______9,6...12Mbps
DeviceNet________125K...500Kbps
Ethernet Modbus TCP 10/100Mbps
See accessories
MICROSWITCHES
8 dip switches are available to select
wiring mode and different functionalities.
POWER
SSR [integrated power element]
Rated voltage: 480Vac
Work voltage range: 24...530Vac
Non-repetitive voltage: 1200Vp
Switching voltage for zero: < 20V
Rated frequency: 50/60Hz (self-adjusting)
Rated current AC51
GFX-4 30kW: 16Amp
GFX-4 60kW: 32Amp
GFX-4 80kW: 57Amp
Non-repetitive overcurrent [t=20msec]
GFX-4 30kW: 400A
GFX-4 60kW: 600A
GFX-4 80kW: 1150A
I2t for melt [t=1...10msec]
GFX-4 30kW: 645A2s
GFX-4 60kW: 1010A2s
GFX-4 80kW: 6600A2s
Dv/dt critical with deactivated output:
1000V/µsec
Rated insulation voltage In/Out:
4000V
GENERAL FEATURES
Power supply:
24Vdc ±25%, max 8VA
Protection class:
IP20
Working temperature range:
0...50°C (see dissipation curves)
Storage temperature range:
-20...+70°C
Relative humidity:
20...85% UR non-condensing
Installation:
EN50022 DIN rail or panel by screw
Dimensions:
ELECTRICAL CONNECTIONS
Triac
Logic/continuous
Relay
1
c (OUT 5...8)
Load 1
OUT 5
no
Load 2
OUT 6
no
Load 3
OUT 7
no
Load 4
OUT 8
no
J1
c
OUT 9
4
3
2
1
4
3
2
1
6
no
J1a
c
OUT 10
9
no
9
POWER SUPPLY
18...32Vdc
S1
S2
Port 1
1
Green
Red
+24Vdc
+VI
Tx/RxTx/Rx+
GNDI
+VI
Tx/RxTx/Rx+
GNDI
J2
S3
Yellow
7
Yellow
1
Yellow
Yellow
IN 5
Yellow
IN 6
S4
J3
Yellow
Port 2
IN 7
IN 8
12
1
IN 1
S5
IN 2
J4
IN 3
IN 4
12
power
Model without fuses-holder
F1 F2
U1 U2
F1 F2
F3 F4
U1 U2
F3 F4
Model with fuses-holder
U3 U4
U3 U4
Model
max current
30kW
16A
60kW
32A (30A)*
80kW
57A (40A)*
0,2 - 6mm2
24-10AWG
0,2 - 6mm2
24-10AWG
0,5 - 16mm2
20-6AWG
0,2 - 4mm2
24-10AWG
0,2 - 4mm2
24-10AWG
0,5 - 10mm2
20-7AWG
0,25 - 4mm2
23-10AWG
0,25 - 4mm2
23-10AWG
0,5 - 10mm2
20-7AWG
0,25 - 4mm2
23-10AWG
0,25 - 4mm2
23-10AWG
0,5 - 10mm2
20-7AWG
rigid
flexible
0,5 - 0,6Nm
* UL certification
0,5 - 0,6Nm
1,2 - 1,5Nm
ORDER CODE
Current (Amp)
Model
GFX4
30
(4x16A)
16
60
(4x32A)
(4x30A)*
80
(4x40A)
40*
range
24...530
32 (30)*
57
Power (kW)
Voltage (Vac)
max
for channel
24...530
24...530
nominal
total
contemporary
single
channel
max for
single channel
110
(4x16x110)
7
(16x110)
1,7
(1x16x110)
1,7
230
(4x16x230)
14,7
(16x230)
3,6
(1x16x230)
3,6
400
(4x16x400)
25,6
(16x400)
6,4
(16x400
6,4
480
(4x16x480)
30,7
(16x480)
7,6
(1x16x480)
7,6
110
(4x32x110)
14
(32x110)
3,5
(32x110)
3,5
230
(4x32x230)
29,4
(32x230)
7,3
(1x32x230)
7,3
400
(4x32x400)
51,2
(32x400)
12,8
(1x32x400)
12,8
480
(4x32x480)
61,4
(32x480)
15,3
(1x32x480)
15,3
110
(4x40x110)
17,6
(40x110)
4,4
(1x57x110)
62,7
230
(4x40x230)
36,8
(40x230)
9,2
(1x57x230)
13,1
(4x40x400)
64
(4x40x480)
76,8
(40x400)
16
(40x480)
19,2
(1x57x400)
22,8
(1x57x480)
27,3
working
480
480
480
400
480
* UL Certificate
GFX4
NOMINAL POWER
FIELDBUS
30KW
30
60KW
60
80KW
0
Absent
M
Modbus RTU
P
Profibus DP
80
C
CANopen
C1
Euromap 66
D
DeviceNet
E
Ethernet Modbus TCP
E1
Ethernet IP
AUXILIARY OUTPUTS
Absent
0
Relay
R
Logic
D
FUSES
Continuous
C
0
Triac
T
F
Absent
fuses-holder + fuses extrarapid (*)
(*) Available only for 30, 60kW power.
AUXILIARY INPUTS
1
1 Current Transformer
2
4 Current Transformers
3
4
1 Current Transformer
+ 4 Linear inputs
4 Current Transformers
+ 4 Linear inputs
GEFRAN spa reserves the right to make aesthetic or functional changes at any time and without notice.
GEFRAN spa via Sebina, 74 - 25050 Provaglio d’Iseo (BS)
Tel. 03098881 - fax 0309839063
Internet: http://www.gefran.com
DTS_GFX4_1008_ENG
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