GEFLEX
GEFLEX
MODULAR POWER CONTROLLER FOR TEMPERATURE CONTROLLED ZONES
OPERATING INSTRUCTIONS
AND WARNINGS
code 80331D / Edition 0.5 - 09/05
TABLE OF CONTENTS
Page
Graphic symbols used
23
1 Preliminary instructions
24
General description
24
2 Installation and Connection
25
2.1 Overall dimensions and mounting dimensions 27
2.2 Description of base
28
2.3 Installation examples
29
2.4 3-phase connection
29
3 Electrical connections
30
3.1 Wire terminal table
30
3.2 Operation of Geflex Master relay
30
3.3 Power connections / Inputs /
Outputs / Power supply
31
3.4 Serial connections
32
3.5 Connection of
Master + Slave modules
33
3.6 Three-phase connection
with neutral
33
3.7 Three-phase connection
without neutral
33
4 Installation of “MODBUS” serial network
4.1 “AUTOBAUD” sequence
4.2 “AUTONODE” sequence
4.3 “CHANGE” sequence
4.4 Software on/off
5 Alarms
5.1 HB alarm function
5.2 HOLD function
6 Control actions
7 Manual Tuning
8 Multiset function, Set Gradient
9 Self-tuning
10 Auto-tuning
11 Controls
11.1 Heating/Cooling control
with relative gain
12 Dissipation curves
13 Technical specifications
14 Technical-Commercial information
14.1 Accessories
Page
34
35
35
36
36
37
37
37
38
38
38
39
39
40
40
40
41
42
43
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
23
Indicates a suggestion based on the experience 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 before
proceeding with controller installation,
configuration and use.
•
Check also that the controller 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, as well as for the GEFLEX Master model, the
“Programming and Configuration manual”.
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 controller is
needed for, referring to Section:
“Technical - Commercial Information”.
General description
Modular controllers GEFRAN series GEFLEX have been
designed for temperature control in any applications involving
heating or cooling processes.
They represent an exclusive combination of
performance, reliability and applicational flexibility.
In particular, this new line of Gefran temperature
controllers is the ideal solution for application in sectors where
performance and service continuity are important, including:
extrusion lines
• injection molding for plastic materials
• thermoformers
• presses for rubber
• wrapping and packaging machines
• processing plant for the food industry
• cooling switchboards
• climatic chambers and test benches
• ovens
• paint plants
• etc.
The GEFLEX series controllers are made on an extremely
versatile hardware and software platform, that allows the most
suitable I/O composition for the plant to be chosen from a series
of options.
Example: GFX-M1 - 40/480 -M - D - RR - P - C0
Master model
Rated
current/voltage
Interface
Field bus
Cooling output
Auxiliary outputs
Digital input
Diagnostics
• Before installing the GEFLEX temperature
controller in the machine control panel or host system, read
paragraph 2.1 "Overall dimensions and mounting
dimensions”.
Attention: the programming and configuration
parameters are described in the "Programming and
Configuration" manual enclosed with the Geflex
Master and downloadable from www.gefran.com
•
Users and/or system integrators who wish to know
more about the concepts of serial communication
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
Preliminary Warnings
The following preliminary warnings should be read
before installing and using the series GEFLEX
controller. 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.
•
If the instrument is to be configured by PC, make sure you
have the WINSTRUM Kit.
For the order code refer to Section "Technical-Commercial
Information”.
Immediately after unpacking the controller, 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.
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 Number)
CODE ......................... (Product code)
TYPE........................... (Order code)
SUPPLY...................... (Type of electrical power supply)
VERS. ......................... (Firmware Version)
VERS. PROFIBUS....... (Fieldbus Version)
24
2 • INSTALLATION AND CONNECTION
Advice for Correct Installation for EMC
This section contains the instructions necessary for
correct installation of the GEFLEX controllers into the
machine control panel or the host system and for
correct connection of the controller power supply,
inputs, outputs and interfaces.
Instrument power supply
•
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 controller 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 controller.
The switch must be located in the immediate vicinity of the
controller and must be within easy reach of the operator.
One switch may control more than one controller.
• if the controller 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 controller 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 controller 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.
•
•
•
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
•
•
•
Notes Concerning Electrical Safety and
Electromagnetic Compatibility:
•
• CE MARKING: EMC Conformity (electromagnetic
compatibility)
in accordance with EEC Directive 89/336/CEE modified by
Directive 93/68.
Series GEFLEX controllers are mainly designed
to operate in industrial environments, installed on the
switchboards or control panels of productive process
machines or plants.
As regards electromagnetic compatibility, the strictest generic
standards have been adopted, as indicated in the table
below.
• BT Conformity (low tension)
in accordance with Directive 73/23/CEE modified by Directive
93/68.
The externally connected circuits must be doubly isolated.
To connect the analogue inputs (TC, RTD) 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 regulating and alarm 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 characteristics of
the controller and to the indications given in
these Instructions for Use.
EMC conformity has been tested with the following connections
(table 1).
25
EMC conformity has been tested with the following connections
FUNCTION
Power supply cable
Relay output cables
Serial connection wire
Power connection cable
Thermocouple input probe
“PT100” temperature resistance input probe
CABLE TYPE
1 mm2
1 mm2
0,35 mm2
see related sections
0,8 mm2 compensated
1 mm2
LENGTH
1 mt
3,5 mt
3,5 mt
3.5 mt
5 mt
3 mt
Table 1
EMC Emission
Generic standards, emission standard for residential
commercial and light industrial environments
Emission enclosure
Emission AC mains
Radiated emission
CEI EN 61000-6-3
CEI EN 61000-6-3
CEI EN 61000-6-3
CEI EN 61326 CISPR 16-2
Group1 Class B
Group1 Class B
Class B
EMC Immunity
Generic standards, immunity standard for industrial
environments
Immunity ESD
CEI EN 61000-6-2
Immunity RF interference
CEI EN 61000-4-3 /A1
Immunity conducted disturbance
CEI EN 61000-4-6
Immunity burst
CEI EN 61000-4-4
Immunity pulse
CEI EN 61000-4-5
Immunity Magnetic fields
Voltage dips, short interruptions and voltage immunity tests
CEI EN 61000-4-8
CEI EN 61000-4-11
CEI EN 61000-4-2
LVD Safety
Safety requirements for electrical equipment for measurement, CEI EN 61010-1
control and laboratory use
26
4 kV contact discharge level 2
8 kV air discharge
level 3
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 MHz80 MHz (level 3)
2 kV power line (level 3)
2 kV I/O signal line (level 4)
Power line-line 1 kV (level 2)
Power line-earth 2 kV (level 3)
Signal line-earth 1 kV (level 2)
100 A/m (level 5)
100%U, 70%U, 40%U,
2.1 Overall dimensions and mounting dimensions
5) Remove the screw fastening the wire to the ground terminal,
and then remove the protective cover from the power terminals
by sliding it upward.
1) Position each GEFLEX module with the longer side aligned
with the vertical axis of the electrical panel to increase
adequate natural air flow to the heat sink. The minimum
distance from the side walls of the panel must be 20 mm; from
the top and bottom walls, the minimum distance must be
100mm.
6) Wire signal terminal boards "J1" and "J2", connect the
INPUT power terminals to Line, OUTPUT to Load and
COMMON to the return phase of Load (see "Electrical
Connections").
2) If a Master (GFX-M2...), install the module at the extreme
left of the space reserved on the electromechanical plate; line
up the Slave (GFX-S2…) or Expansion (GFX-E2…) modules
progressively to the right of the Master, for a maximum of ten
modules in all (see "Connection Examples").
7) Attach the protective cover of the power terminals and
connect the wire to the ground terminal.
8) If the module is a Master (GFX-M2...), wire its connector to
the serial interface see "Electrical Connections").
3) The distance between the modules is shown on the attached
drawing. The minimum distances can be used if the actual
current is less than or equal to 75% of the maximum current
shown on the GEFLEX data plate.
9) If the module is a Slave (GFX-S2...) or Expansion (GFXE2...), attach the flat wire to the corresponding connector "J3"
of the module immediately to the left (see "Connection
Examples").
4) Attach each GEFLEX module to the electromechanical plate
by means of DIN EN50022 guide or directly with 5MA screws
(see "Dimensions and Cutout").
10) If the module is a Expansion (GFX-E1…) with option “C0”
or “CV” attach the flat wire corresponding (see three-phase
connection).
h
h (mm)
160
195
224
25/40A
60A
75/90/120A
41
82
127
25
53
53
25
53
27
212
212
212
40
25A
40A ... 120A
53
2.2 Description of base
GEFLEX 25A - 40A
GEFLEX 60A - 75A - 90A - 120A
• Power
"High voltage" lamp"
Connection key to DIN EN50022 guide
"Load output" connection
"Load common" connection
"Line input" connection
Ground connection
• Control and Communication
Led L2 "Error" LED (red)
Activates when one of the following errors is present:
LO = process variable value is < di Lo.S
HI = process variable value is > di Hi.S
Sbr = broken probe or input values beyond maximum
limits
Err = third wire broken for Pt100, PTC or input values
below minimum limits
(ex.: for CT with incorrect connection)
Led L3 “Main” (yellow)
Follows trend of
heat output (OUT1)
Led L1 “Status” (green)
Freely settable with parameter
197 (Ld.St).
Default setting is16
(RUN flashes)
Field bus node selection
J3
Connection to next module
J2
Output terminal board
Connection to previous module
(only Slave and Expansion modules)
J1
Probe and power supply terminal board
Fieldbus connection
(only Master modules)
• Configuration of cooling output
If you use the continuous cooling output (order code "C"), you
can use a selector to change the factory setting from voltage
(0/2...10V) to current (0/4...20mA).
Use a screwdriver to access the
selector through the slot.
28
300 min
2.3 Connection examples
GFX 25 - 40
45 min
90 max
GFX 75 / 90 / 120
GFX 60
67,5 min
90 max
90 min
135 max
112,5 min
135 max
135 min
135 max
GFX 25 - 40
90 min
90 max
AIR FLOW
2.4 3-phase connection
Master/Slave
st
1 expansion
nd
Connection cable to previous module
2 expansion
Male connector on all Master/Slave models.
Remove the cover in case of use.
Connection cable to previous Master/Slave module
(present only if the expansion has a current
transformer) to detect current in the expansion.
Connection cable to
previous module
Check that the G.TA data shown on the expansion label equals the G.TA2 value (for the first expansion) and the G.TA3
value (for the second expansion) of the connected Master/Slave”.
For more information, see the "Configuration and Programming" manual
29
3 • ELECTRICAL CONNECTIONS
SIGNAL
POWER
3.1 Wire terminal table
Level
Terminal contact
area (LxD)
Terminal hole
diameter
Recommended
conductor section
25A
12 x 12mm
5mm
6mm2
40A
12 x 12mm
5mm
10mm2
60A
14 x 12mm
6mm
16mm2
75A/90A
14 x 12mm
6mm
25mm2
120A
14 x 12mm
6mm
35mm2
Conductor with prod terminal with
insulating collar
0,25 - 0,5mm2 / 24-20AWG
Flexible wire conductor
0,14 - 1,5mm2 / 28-16AWG
Cross-cut screwdriver, blade 0.4 x 2.5mm
3.2 Operation of Geflex "Master" relay
The "OUT3" and "OUT4" relays on the Geflex Master module provide special functions designed to reduce user wiring. These functions are
active even when the Geflex Master module is not powered.
• The "OUT3" relay can be energized by the "rL3" command of the Geflex Master and by the "rL5" command of each Geflex Slave. This "OR"
function of alarms among the devices can be used, for example, for a "maximum temperature setpoint" alarm in each zone to be heated by
appropriately configuring the "Ax.t" parameters.
Geflex Master “rL3”
Geflex Master “OUT3”
Geflex Slave “rL5”
Geflex Slave “rL5”
Output "OUT3" can function independently of the state of the Geflex Slaves by setting parameter "rL5" to 128 on each Geflex Slave.
• The "OUT4" relay can be energized only with the simultaneous presence of the "rL4" command of the Geflex Master and commands "rL6" of
all the Geflex Slave. This "AND" of alarms among the devices can be used, for example, to signal "minimum temperature setpoint reached" in
each zone to be heated by appropriately configuring the "Ax.t" parameters.
Geflex Master “rL4”
Geflex Slave “rL6”
Geflex Slave “rL6”
Geflex Master “OUT4”
Output "OUT4" can operate independently of the state of the Geflex Slaves by setting parameter "rL6" to 160 (128+32) on each Geflex Slave.
For more information, see the "Configuration and Programming" manual”.
30
3.3 Power / Input / Output / Power Supply connections
Three-phase line with neutral
FUSE
LOAD
Output
Common
Input
Three-phase line without neutral
LOAD
FUSE
Output
Common
Input
The Input and Common connection to the network depend on the
application.
A wire with 0,5mm2 / 20AWG section is sufficient for the Common
connection; tightening torque screws: 4Nm
Pt100 LIN INP LIN INP
3 wires Idc (20mA) Vdc (1V)
+
+
T
TC
J1- 1
2
3
+
4
5
6
7
L+ Digital input
L+
M
Power supply (18...32Vdc)
PE
J3
J1
1
1
OUT 1 internal command for
solid state relay (HEAT)
7
8
J2
8
7
5
4
2
J2- 1
J1: Probe and power supply terminal board
J2: Relay output terminal board
31
C3
OUT 4 (AL2)
NA3
C2
OUT 3 (AL1)
NA2
C1
(+)
NA1 (-)
OUT 2 (COOL)
(Output 2 with
“Logic” PNP18...32Vdc and
“Continuous” 0...10Vdc / 0...20mA options
not isolated from power supply)
3.4 Serial connections
“PROFIBUS DP” serial
“MODBUS” serial
D-SUB Connector
9-pin Male
Shielded cable 1 pair 22 AWG
MODBUS conformity
TX / RX+
TX / RX-
D-SUB connector
9-pin Male
Shielded cable 1 pair 22 AWG
PROFIBUS conformity
From previous module
on Modbus network
From PROFIBUS
network
SCH
GND
TX / RX+
TX / RX-
To next module on
Modbus network
We advise you to connect a 220Ω 1/4W resistance between
the "RxD/TxD-P" and "RxD/TxD-N" signals, a 390Ω 1/4W
resistance between the "RxD/TxD-P" and "Vp" signals, and a
390Ω 1/4W resistance between the "RxD/TxD-N" and
"DGND" signals at both ends of the Profibus network.
We advise you to connect pins 6 to 7 and pins 8 to 9 on the
connector of the last Geflex on the Modbus network to insert
the line termination.
“CANopen” serial
TX / RX+
TX /
TX / RX-
GND
D-SUB Connector
9-pin Female
From Modbus network
Shielded cable 2 pairs 22/24 AWG
CANopen conformity
From CANbus network
It is also advisable to connect the "GND" signal between
Modbus devices having a line distance > 100m.
We advise you to connect a 120Ω 1/4W resistance between
the "CAN_L" and "CAN_H" signals at both ends of the
CANbus network.
“DeviceNet” serial
5
CAN_H
3
V+
4
Connector 5 pin
SHIELD
From DeviceNet network
2
CAN_L
Shielded cable 2 pairs 22/24 AWG
DeviceNet conformity
1
V-
We advise you to connect a 120Ω 1/4W resistance between
the "CAN_L" and "CAN_H" signals at both ends of the
DeviceNet network.
32
M
S1
FUSE 10
LOAD 10
FUSE 2
FUSE 1
LOAD 2
LOAD 1
3.5 Connection of MASTER + SLAVE modules
S9
FIELDBUS
SLAVE1
MASTER
SLAVE9
To next
GEFLEX Master
3.6 Three-phase connection
Three-phase connection with neutral
GFX 40A/480Vac
AC1 50/60Hz
GFX 40A/480Vac
AC1 50/60Hz
M
E1
Intelligent Power Unit
Intelligent Power Unit
Three-phase connection without neutral
GFX 40A/480Vac
AC1 50/60Hz
Intelligent Power Unit
GFX 40A/480Vac
AC1 50/60Hz
GFX 40A/480Vac
AC1 50/60Hz
GFX 40A/480Vac
AC1 50/60Hz
S1
E3
E4
Intelligent Power Unit
E2
FIELDBUS
MASTER
To next
GEFLEX Master
33
Intelligent Power Unit
Intelligent Power Unit
4. INSTALLATION OF MODBUS SERIAL NETWORK
the following protocols: ModBus, Profibus or CANopen.
The following procedures are to be considered indispensable
for the ModBus protocol.
For the other protocols, refer to the specific Geflex Profibus and
Geflex CANopen manuals.
GEFLEX modules are supplied preset for 19200 baud without
parity and with rotary selector for node address “0”.
A maximum of ninety GEFLEX modules can be installed in a
serial network, with node address selectable from “10” to “99”.
In a network, there is typically a Master that "manages"
communication by means of “commands" and Slaves that
interpret these commands.
Geflex Masters are to be considered slaves to the network
master, which is usually a supervision terminal or PLC.
In addition, both the Geflex Masters and Slaves are identified in
an unequivocal manner by means of a node address (ID).
The Geflex Master differs from the Geflex Slave only because
the Geflex Master can be connected to the fieldbus.
In addition, the Geflex Master shows the state of the Geflex
Slave on its outputs "OUT4" and "OUT5" by means of the OR
and AND functions:
The Geflex Masters are available (see order code) with one of
INSTALLATION
SERIAL NETWORK
YES
?
Serial network communication
speed is 19200 baud
NO
"AUTOBAUD"
SEQUENCE
First installation of network
Green "STATUS" LED
flashes at 5Hz
?
Green "STATUS" LED
flashes at 10Hz
Replacement or addition of a module
Master
"AUTONODE"
SEQUENCE
?
Slave
SETTING THE
NODE
ADDRESS
OPERATIVE
FUNCTION
34
"CHANGE"
SEQUENCE
Green "STATUS" LED
flashes at 2Hz
Green "STATUS" LED
flashes at 5Hz of
master
4.1 “AUTOBAUD” sequence
5) Check that the green "STATUS" LEDs are flashing at high
frequency (10Hz).
Adjust the serial communication speed and parity of the Geflex
models to the supervision terminal or PLC.
If network speed is 19200 baud and there is no parity, go
directly to the "AUTONODE" sequence.
6) The supervision terminal has to transmit a series of generic
"MODBUS" read messages to the network.
The green "STATUS" LED L1 mentioned in the
procedure can vary its behavior based on parameter
Ld.St , which has a default setting of 16.
The red LED not mentioned in the procedure can
vary its behavior based on the presence of an error
on the main input.
7) The procedure is finished when all of the green "STATUS"
LEDs L1 on the Geflex modules flash at a normal frequency
(2 Hz). (If parameter 197 Ld.St = 16 as default.).
The new speed parameter is saved permanently in each
Geflex, so you will not have to activate the "AUTOBAUD"
sequence at future power-ups.
1) Cut power to the Geflex modules.
2) Connect the serial cables to all of the Master modules
(GFX-M1…) in the network and to the supervision terminal.
Steps 1 and 4 are necessary only for Geflexes with
firmware 1.0x. In later versions, when the rotary
selector is moved, the green "STATUS" LED
remains on steadily for about 6 seconds, after which
it resumes its normal operation, saving the address.
3) Set the rotary selector on the Geflex modules to be installed
(or on all the module in case of a first installation) to “0”.
4) Turn on power to the electrical pane.
4.2 “AUTONODE” sequence
6) Disconnect the serial cable from each Geflex Master.
Each GEFLEX module has to be assigned an unequivocal
node address in the serial network.
If the entire network was previously initialized and you want to
add a new module to the network, go directly to the "CHANGE"
sequence. The node address is assigned by means of the
rotary selector on each module.
Geflex Master modules can assume tens values only 1 = 10, 2
= 20, ... 9 = 90.
(ex. Geflex Master rotary selector = 2, node address = 20)
Geflex Slave modules can assume only the values that are the
sum of their own rotary selector (representing units) plus the
tens set on the connected master.
(ex. Geflex Master rotary selector = 2, node address = 20; Geflex
Slave rotary selector = 3, node address = 20+3= 23).
7) Turn the rotary selector of the Master module to position "A".
8) Energize the electrical panel.
9) Check that the green "STATUS" LED on the Master module
flash at a frequency of about 5Hz.
10) The procedure is finished when the green "STATUS" LED
and red "ERR" LED flash at a frequency of about 2Hz.
11) Turn the power off.
12) Connect the serial cable to each Geflex Master.
The green "STATUS" LED L1 mentioned in the
procedure can vary its behavior based on parameter
Ld.St , which has a default setting of 16.
The red LED not mentioned in the procedure can
vary its behavior based on the presence of an error
on the main input.
13) Return the rotary selector on the Master module to the
position assigned at point 3.
The new node address parameter is saved permanently in
each Geflex, so you will not have to activate the "AUTONODE"
sequence at future power-ups.
1) Cut power to the Geflex modules.
Steps 1, 4, 5, 8 and 11 are necessary only for
Geflexes with firmware 1.0x. In later versions, when
the rotary selector is moved, the green "STATUS"
LED remains on steadily for about 6 seconds, after
which it resumes its normal operation, saving the
address.
2) Set the rotary selector on the Slave modules (GFX-S1...) in
progression from "1" to "9".
3) The rotary selector on the Master modules (GFX-M1..) must
be set from "1" to "9".
4) Energize the electrical panel, check that the green
"STATUS" LEDs flash at a frequency of 2Hz. (If parameter 197
Ld.St = 16 as default). In this step, each module has acquired
the status of its rotary selector.
5) Cut power to the Geflex modules.
35
4.3 “CHANGE” sequence
This is necessary when replacing a module or adding a new
module to the network in order to assign a correct node
address and communication speed.
For a Master module (GFX-M1...), simply set the rotary selector
to the position you want, then energize the electrical panel.
For a Slave module (GFX-S1...), do as follows.
9) The procedure is finished when all of the green "STATUS"
LEDs flash at a normal frequency (2 Hz).
1) Cut power to the Geflex modules.
12) Return the rotary selector on the Geflex Master to the
position assigned at point.
10) Cut power to the Geflex modules.
11) Connect the serial cable to the Geflex Master module.
2) Disconnect the serial cable from the Geflex Master.
The new node address parameter is saved permanently in
each Geflex, so you will not have to activate the "AUTONODE"
sequence at future power-ups.
3) Turn the rotary selector of the Slave to be inserted to
position “0”.
Steps 1, 4, 5, 8 and 11 are necessary only for
Geflexes with firmware 1.0x. In later versions, when
the rotary selector is moved, the green "STATUS"
LED remains on steadily for about 6 seconds, after
which it resumes its normal operation, saving the
address.
4) Turn the rotary selector of the Master to position “A”.
5) Turn on power to the Geflex modules.
6) Check that the green "STATUS" LED of the Slave is flashing
at high frequency (10 Hz).
7) Check that the green "STATUS" LED of the Master is
flashing at medium frequency (5Hz).
8) During this phase, the new module learns the speed and
address (decimal part).
4.4 Software On/Off
2) Digital input (if present) enabled only if linked to SW
shutdown function
This function is obtained with the digital input if configured
(diG = 6).
All outputs (control and alarms) are OFF (logic level 0, relays
de-energized) and all the instrument control functions are
inhibited except for "ON" function and serial dialog.
The PV input continues to be sampled
3) In case of restart after SW shutdown, the ramp linked to the
set starts from the PV
4) Outputs OFF: except for OUT4 (Master) and OUT6 (Slave)
of the Geflex instrument, which are forced ON
If software on/off is performed, you will have the following
consequences:
5) Reset HB alarm
1) Reset Auto-tuning, Self-tuning and Soft-start functions
6) Reset LBA alarm
36
5. ALARMS
Normal absolute alarm
Symmetrical absolute alarm
AL2
AL1 + [ Hyst1 *]
AL2 + Hyst2
AL1
AL1 + Hyst1
AL1
AL1 - [ Hyst1 *]
time
alarm 1
time
(*)
inverse
direct
alarm 2
For AL1 = symmetrical Lo absolute alarm with Hyst1, AL1 t = 5
For AL1 = symmetrical Hi absolute alarm with Hyst1, AL1 t = 4
(*) min. Hyst = 2 scale points
For AL1 = reverse absolute alarm (low) with positive Hyst1, AL1 t = 1
(*) = OFF if disabled on power-up
For AL2 = direct absolute alarm (high) with negative Hyst2, AL2 t = 0
Deviation alarm
Symmetrical deviation alarm
SP+AL1
SP
SP-AL1
SP+AL1
SP
Hyst1
time
time
inverse
inverse
direct
direct
For AL1 = Lo deviation alarm with negative Hyst 1, AL1 t = 3
For AL1 = Hi deviation alarm with negative Hyst 1, AL1 t = 2
For AL1 = Symmetrical Lo deviation alarm with Hyst 1, AL1 t = 7
For AL1 = Symmetrical Hi deviation alarm with Hyst 1, AL1 t = 6
5.1 HB alarm function
This type of alarm can indicate variations of load current
measured through transformer input in the range (0 ...
HS.tA).
It is enabled by means of configuration code (AL.n); in this
case the alarm setpoint is expressed as HB scale points.
The alarm function and the control output OUT1 are selected
through parameter Hb.F (“Out” phase).
The alarm setpoint is A.Hb.
The direct HB alarm trips if current transformer input falls
below the setpoint for Hb.t seconds of “ON” time for the
selected output.
The HB alarm can be activated only with ON times exceeding
0.4 seconds (excluding the continuous output).
When the voltmeter input option is present, any alarm is
canceled for voltage values below ⁄ of full scale.
The HB alarm monitors load current even during the OFF
period of the cycle time of the selected output.
The HB alarm will trip if measured current exceeds 12,5% of
the selected full scale (parameter HS.tA in InP) for Hb_t
seconds when the output is in OFF state.
The alarm is reset automatically when alarm conditions have
been cleared.
If A.Hb = 0, both types of HB alarm are disabled and the
assigned relay is de-energized.
The current value is available in the IntA register.
NOTE: ON/OFF times refer to the cycle time set for the
selected output
Alarm Hb_F = 3 (7) for analog output is ON when the load
current is lower than the alarm setpoint; the alarm is disabled
if the heating (cooling) output is lower than 3%.
5.2 HOLD function
The input value and trip points are "frozen" while the logic
input is active.
By activating the Hold input with the variable at a value below
the trip points, a reset of the trip point memory de-energizes
all energized relays and resets the memory of all alarms.
37
6. CONTROL ACTIONS
Proportional Action:
action in which contribution to output is proportional to deviation at input (deviation = difference between controlled variable and setpoint).
Derivative Action:
action in which contribution to output is proportional to rate of variation input deviation.
Integral Action:
action in which contribution to output is proportional to integral of time of input deviation.
Influence of Proportional, Derivative and Integral actions on response of process under control
* An increase in P.B. reduces oscillations but increases deviation.
* A reduction in P.B. reduces the deviation but provokes oscillations of the controlled variable (the system tends to be unstable if P.B. value is
too low).
* An increase in Derivative Action corresponds to an increase in Derivative Time, reduces deviation and prevents oscillation up to a critical
value of Derivative Time, beyond which deviation increases and prolonged oscillations occur.
* An increase in Integral Action corresponds to a reduction in Integral Time, and tends to eliminate deviation between the controlled variable
and the setpoint when the system is running at rated speed.
If the Integral Time value is too long (Weak integral action), deviation between the controlled variable and the setpoint may persist.
Contact GEFRAN for more information on control actions.
7. MANUAL TUNING
A) Enter the setpoint at its working value.
B) Set the proportional band at 0.1% (with on-off type setting).
C) Switch to automatic and observe the behavior of the variable. It will be similar to that in the figure:
Process
Variable
D) The PID parameters are calculated s follows: Proportional band
Peak
P.B.= ---------------------------------------- x 100
V max - V min
T
Peak
Time
(V max - V min) is the scale range.
Integral time It = 1,5 x T
Derivative time dt = It/4
E) Switch the unit to manual, set the calculated parameters. Return to PID action by
setting the appropriate relay output cycle time, and switch back to Automatic.
F) If possible, to optimize parameters, change the setpoint and check temporary
response. If an oscillation persists, increase the proportional band. If the response is
too slow, reduce it.
8. MULTISET FUNCTION, SET GRADIENT
SP
SP2
SP1
SPrem
(*)
SP1
t
IN1
ON
t
LOC/REM
ON
t
The multiset function is enabled in hd.1.
The gradient function is always enabled.
Selection of set point 1 or set point 2 can be made by digital input.
The selection of set point 1 / 2 can be displayed by LED.
SET GRADIENT: if set to 0, the setpoint is assumed equal to PV at
power-up and when switching between auto/man; with gradient set, it
reaches the local set or the one selected.
Every variation of the set is subject to a gradient.
The set gradient is inhibited at power-up when self-tuning is enabled.
If the set gradient is set to 0, it is active even with variations of local
setpoints.
The control setpoint reaches the set value at a speed defined by the
gradient.
The value of remote setpoint SP.rS is not saved in EEPROM.
(*) if the set gradient
is set.
38
9. SELF-TUNING
The function works for single output systems (heating or cooling).
The self-tuning action calculates optimum control parameter values during process startup.
The variable (for example, temperature) must be that assumed at zero power (room temperature).
The controller supplies maximum power until an intermediate value between starting value and setpoint is reached, after which it zeros power.
PID parameters are calculated by measuring overshoot and the time needed to reach peak.
When calculations are finished, the system disables automatically and the control proceeds until the setpoint is reached.
How to activate self-tuning:
A. Activation at switch-on
1. Adjust setpoint to required value
2. Enable self-tuning by setting Stu parameter to 2
3. Switch unit off
4. Make sure that temperature is approximately room temperature
5. Switch the unit on
Process
variable
S.P.
Peak
S.P. - t.a.
2
B. Activation by serial command
1. Make sure that temperature is approximately room temperature
2. Adjust setpoint to required value
3. Give the Start Self-tuning command
T
t.a.
Time
The procedure runs automatically until finished, when the new PID parameters are stored: proportional band, integral and derivative times
calculated for the active action (heating or cooling). In case of double action (heating or cooling), parameters for the opposite action are
calculated by maintaining the initial ratio between parameters. (example: Cpb = Hpb * K; where K = Cpb / Hpb when selftuning starts). When
finished, the Stu code is automatically cancelled.
Notes:
- The procedure interrupts when the setpoint value is exceeded. In this case, the Stu code is not cancelled.
- It is good practice to enable one of the configurable LEDs to signal self-tuning status.
By setting Hrd parameter Ld.St = 4 on the Hrd , the corresponding LED will be on or flashing when self-tuning is active.
N.B. Action not considered in ON/OFF control.
10. AUTO-TUNING
During the auto-tuning phase, changes in PID parameters are not considered.
Auto-tuning continuously measures system oscillations to find the optimum AID values to reduce such oscillations. It does not
engage if the oscillations drop below 1.0% of the proportional band.
It is interrupted if the setpoint is changed, and is automatically resumed when the setpoint stabilizes. The calculated
parameters are not stored. If the unit is switched off, the controller reverts to the values set before self-tuning was enabled.
Auto-tuning with switching to Manual ends the procedure.
39
11. CONTROLS
PV
PV
c_Pb
SP+cSP
SP
c_Pb
SP+cSP
SP
h_Pb
h_Pb
time
time
+100%
Control output
0%
+100%
Control output
0%
-100%
-100%
Control output with proportional action only if proportional heating band
is separated from proportional cooling band.
Control output with proportional action only if proportional heating band
overlaps proportional cooling band.
PV = process variable
SP+cSP = cooling setpoint
c_Pb = proportional cooling band
SP = heating setpoint
h_Pb = proportional heating band
11.1 Heating/Cooling control with relative gain
In this control mode (enabled with Ctr = 14 parameter) the type of cooling has to be specified.
Cooling PID parameters are therefore calculated based on heating parameters according to the specified ratio.
(e: C.ME = 1 (oil), H_Pb = 10, H_dt =1, H_It = 4 implies: C_Pb = 12,5, C_dt = 1 , C_It = 4)
We advise you to apply the following values when setting output cycle times:
Air
T Cool Cycle = 10 sec.
Oil
T Cool Cycle = 4 sec.
Water
T Cool Cycle = 2 sec.
NB.: Cooling parameters cannot be modified in this mode.
12. DISSIPATION CURVES
Rated current curves based on room temperature.
Geflex 25
Geflex 40
Geflex 75
Geflex 90
Geflex 60
Geflex 120
Dissipated Thermal Power:
Pds = 1.6 x Irms (W)
Irms = rated current of single-phase load
N.B.: Geflex 120 curves refer to the device complete with standard fan running.
40
13 • TECHNICAL SPECIFICATIONS
Inputs
Accuracy main input
Thermal drift
Main input
(configurable digital filter)
0,2% f.s. ±1 scale points at 25°C ambient temperature
0,005% f.s. / °C
TC, RTD 60mV,1V Ri≥1MΩ; 20mA Ri=50Ω
Sampling time 120 msec.
J, K, R, S, T, (IEC 584-1, CEI EN 60584-1, 60584-2)
Type TC (Thermocouples) (ITS90) a custom linearization can be inserted
Cold junction error 0,1° / °C
RTD type (scale settable in indicated range, DIN 43760 (Pt100), JPT100
with/without decimal point) (ITS90)
Max. line resistance for RTD 20Ω
Accuracy current transformer input 1% f.s. ± 1 scale points at 25°C ambient temperature
Current transformer input Internal CT 0...120A Sampling time 480msec. (1 fase), 1440msec. (3 fasi)
Accuracy voltage transformer input 10% f.s. ± 1 scale points at 25°C ambient temperature on the range 0...100Vac and 400...500Vac
5% f.s. ± 1 scale point at 25°C ambient temperature on the range 100...400Vac
Voltage transformer Internal VT 0...500Vac. Sampling time 480msec (1 fase), 1440msec (3 fasi)
Logic input 24V, 8mA
Functionality
Safety Detection of short circuit or opening of probes, LBA alarm, HB alarm
°C / °F selection Configurable
Linear scale ranges -1999...9999
Controls Pid, Autotune, on-off
pb - dt - it 0,0...999,9 % - 0,00...99,99 min - 0,00...99,99 min
Action - Control outputs heat / cool - on / off, PWM, GTT
Max. power limit heat / cool 0,0...100,0 %
Cycle time - Softstart 0...200 sec - 0,0...500,0 min
Fault power setting -100,0...100,0 %
Automatic blanking Maintains sampling of process variable PV; when active, disables the control
Up to 4 alarm functions assignable to an output and configurable of type: maximum, minimum,
Configurable alarms symmetrical, absolute/relative, LBA, HB
Alarm masking Exclusion during warm up memory, reset from digital input
Outputs
2 relay outputs NO, 3A, 250V cosϕ=1
2 logic outputs 24Vdc, 35mA
2 continuous outputs 0/2...10V, 0/4...20mA su 500Ω max.
Power supply
Power supply 24Vdc ±25%, 5W max. Remote class 2 source or limited current
Serial
Serial interface
Baude rate
Protocol for Geflex master
Optional field bus protocols
General characteristics
Indications
Protection
Working / storage temperature range
Relative humidity
Installation
RS485, optoisolated
1200, 2400, 4800, 9600, 19200
MODBUS RTU
CANopen 10K...1Mbit/sec PROFIBUS DP 9,6...12Mbit/sec
3 LEDs (diagnostics) + lamp (presence of high voltage)
IP20
0...40°C / -20...70°C; Maximum surrounding air temperature 40°C
20...85% Ur not condensing
Barra DIN EN50022 or pannel from 5MA screws
25A
40A
60A
75A
90A
120A
Weight max 650gr
850gr
1300gr
1500gr
1500gr
1600gr
SSR
Nominal voltage
Rated working voltage
Non-repetitive voltage
Switching voltage for zero
Rated frequency
Rated current AC1
Non-repetitive overcurrent (t=20ms)
I2t for blowout (t=1...10ms)
dv/dt critical with output deactivated
Rated isolation voltage IN/OUT
Working temperature
480Vac
24...253Vac
1200Vp
≤ 20V
50...60Hz
25A
40A
≤ 400A
≤ 600A
≤ 645A2s
≤ 1010A2s
1000V/µs
4000V
see dissipation curves
60A
≤ 1150A
≤ 6600A2s
41
75A
≤ 1500A
≤ 8000A2s
90A/120A
≤ 1500A
≤ 11200A2s
14 • TECHNICAL-COMMERCIAL INFORMATION
This section contains information on the order codes
for the Controller and on main accessories.
permits immediate identification the controller's hardware
configuration. It is therefore essential to give the order code
each time you have to contact Gefran's Customer Care Service
to solve any problems.
As specified in the Preliminary Warnings of these Operating
Instructions, correct interpretation of the Controller order code
Master
GFX-M1
RR
480
P
RATED CURRENT
DIAGNOSTIC
Base Master 25-40A
without solid state power unit
B40
Base Master 60-120A
without solid state power unit
B120
25A
25
40A
40
60A
60
75A
75
90A
90
120A
120
Absent
C0
Current Transformer
CV
Current Transformer
+ Voltage Transformer
DIGITAL INPUT
P
0
Absent
D
Logic
R
Relé
C
Continuous output
0...10V (0/4...20mA)
00
Absent
C0
Current Transformer
CV
Current Transformer
+ Voltage Transformer
FIELD BUS INTERFACE
M
PROFIBUS DP
P
CAN OPEN
C
DeviceNet
D
Slave
GFX-S1
2 Relays
COOLING OUTPUT
480
RS485 MODBUS
PNP Digital Input
AUXILIARY OUTPUTS
RR
RATED VOLTAGE
480Vac
00
480
0
P
DIAGNOSTIC
RATED CURRENT
Base Master 25-40A
without solid state power unit
B40
Base Master 60-120A
without solid state power unit
B120
25A
25
40A
40
60A
60
75A
75
90A
90
120A
120
DIGITAL INPUT
P
PNP Digital Input
AUXILIARY OUTPUTS
00
Absent
RR
2 Relays
(**)
RATED VOLTAGE
480Vac
480
(**) Option not available for current levels 75A, 90A and 120A
COOLING OUTPUT
Absent
0
Logic
D
Relay
R
Continuous output
0...10V (0/4...20mA)
C
Expansion
GFX-E1
480
0
0
00
0
RATED CURRENT
DIAGNOSTIC
Base Master 25-40A
without solid state power unit
B40
Base Master 60-120A
without solid state power unit
B120
25A
25
40A
40
60A
60
75A
75
90A
90
120A
120
00
Absent
C0
Current Transformer
CV
Current Transformer
+ Voltage Transformer
RATED VOLTAGE
480
480Vac
GEFRAN spa reserves the right to make aesthetic or functional changes at any time and without notice.
42
14.1 Accessories
KIT WINSTRUM
Software for management / configuration of Geflex units.
The main parameters of all Geflex models can be varied with a simple, intuitive interface.
ORDER CODE
Winstrum software on CD, RS232/485 converter complete
with cables to connect the PC and the Geflex . . . . . . . . . . . . . . . . . . . . .WSK - 1 - 1 - 0
GFX-OP
Operator terminal for field configuration of the entire Geflex range
Two types of terminals are available:
- for installation on the Geflex heatsink or on DIN guide
- for installation on the faceplate
ORDER CODE
Programming terminal for Geflex (installation on DIN guide or on heatsink),
complete with connection cable to Geflex (L = 0.2 m) . . . . . . . . . . . . . . . . . . .GFX-OP-D
Note: see cable section for other cable lengths
Programming terminal for Geflex (installation on faceplate) . . . . . . . . . . . . . . .GFX-OP-P
Note: see cable section for connection cable
Kit consists of:
power supply, connection cable PC <--> GFX-DP-D (L = 2 m),
power adapter for the Geflex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GFX-OP-K
FUSES
FUSE HOLDERS
ORDER CODE
ORDER CODE
GFX 25 . . . . . .FUS-025 (10x38mm)
GFX 40 . . . . . .FUS-040 (14x51mm)
GFX 60 . . . . . .FUS-080 (22x58mm)
GFX 90 . . . . .FUS-100 (22x58mm)
GFX 120 . . . . .FUS-125N (100x51x30mm)
non-extractable
PF - 10x38 . . .(for FUS-025)
PF - 14x51 . . .(for FUS-040)
PF - 22x58 . . .(for FUS-080, FUS-100)
PF - DIN . . . . .(for FUS-125N)
KIT TO ADAPT GTS MODULES TO
GEFLEX BASE
Kit consisting of set of reeds with nickel-plated copper contact, pad-printed cover with
hook cursor.
Permits installation of GTS series solid state power relays on the Geflex base.
ORDER CODE
Kit to insert GTS-25A on Geflex BASE Master/Slave 25-40 . . . . . . . . . . . . . . . .CGK-25
Kit to insert GTS-40A on Geflex BASE Master/Slave 25-40 . . . . . . . . . . . . . . . .CGK-40
Kit to insert GTS-60A on Geflex BASE Master/Slave 60-120 . . . . . . . . . . . . . . .CGK-60
Kit to insert GTS-75A on Geflex BASE Master/Slave 60-120 . . . . . . . . . . . . . . .CGK-75
Kit to insert GTS-90A on Geflex BASE Master/Slave 60-120 . . . . . . . . . . . . . . .CGK-90
Kit to insert GTS-90A on Geflex BASE Master/Slave 60-120 . . . . . . . . . . . . . .CGK-120
Note: See the Geflex catalog for more accessories.
43
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