INSTALLATION AND CONNECTION
This section contains the instructions needed for correct installation of GTF controllers on the machine/host system
control panel and for correct connection of the power supply, inputs, outputs and interfaces.
CAREFULLY READ THE FOLLOWING WARNINGS BEFORE INSTALLING THE INSTRUMENT!
Disregard of such warnings could create electrical safety and electromagnetic compatibility problems, as well as void the warranty.
ELECTRICAL POWER SUPPLY
• the controller DOES NOT have an On/Off switch: the user must install switch/isolator conforming to safety requisites
(CE mark) to cut off the power supply up-line of the controller.The switch must be installed in the immediate vicinity of the controller in easy reach of the operator. A single switch can be used for multiple devices.
* the earth connection must be made with a specific lead
• if the product is used in applications with risk of harm to persons or damage to machines or materials, it MUST be
equipped with auxiliary alarm devices.
It is advisable to provide the ability to check for tripped alarms during regular operation.
NOTES ON ELECTRICAL SAFETY AND ELECTROMAGNETIC COMPATIBILITY
CE MARKING: EMC (electromagnetic compatibility) conformity in compliance with Directive 2014/30/EU and following modifications.
Series GTF controllers are mainly intended for industrial use, installed on panels or control panels of production process machines or systems.
For purposes of electromagnetic compatibility, the most restrictive generic standards have been adopted, as shown on the table.
LV (low voltage) conformity in compliance with Directive 2014/35/EU.
EMC conformity has been verified with the connections indicated on table 1 (see user’s manual).
RECOMMENDATIONS FOR CORRECT INSTALLATION FOR PURPOSES OF EMC
Instrument power supply
• The power supply for the electronic instrumentation on the panels must always come directly from a cut-off device with fuse for the instrument part.
• Electronic instrumentation and electromechanical power devices such as relays, contactors, solenoids, etc., MUST
ALWAYS be powered by separate lines.
• When the power supply line of electronic instruments is heavily disturbed by switching of thyristor power groups or
by motors, you should use an isolation transformer only for the controllers, grounding its sheathing.
• It is important for the system to be well-grounded:
- voltage between neutral and ground must not be > 1V
- Ohmic resistance must be < 6Ω;
• If the grid voltage is highly unstable, use a voltage stabilizer.
• In proximity of high-frequency generators or arc welders, use adequate grid filters.
• The power supply lines must be separate from instrument input and output lines.
• Supply from Class II or from limited energy source.
Input and output connections
Before connecting or disconnecting any connection, always check that the power and control cables are isolated from voltage.
Appropriate devices must be provided: fuses or automatic switches to protect power lines.
The fuses present in the module function solely as a protection for the GTF semiconductors.
• Connected outside circuits must be doubly isolated.
ELECTRICAL CONNECTIONS
C onneCtions
i nput
/o utput
GTF 25-120A
Top view WITH OUT option Fieldbus
Key HB
Top view OUT option Fieldbus
Key HB
Low view
WITHOUT option RS485 serial line
• it’s necessary 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.
Installation notes
Use the extra-rapid fuse indicated in the catalogue according to the connection example equipped.
- Moreover, the applications with solid-state units require a safety automatic switch to section the load power line.
To ensure maximum reliability, the device must be correctly installed in the panel in such a way as to obtain adequate heat exchange between the heat sink and the surrounding air under conditions of natural convection.
Fit the device vertically (maximum angle 10° to the vertical axis)
• Vertical distance between a device and the panel wall >100mm
• Horizontal distance between a device and the panel wall at last 20mm
• Vertical distance between a device and the next one at last 300mm.
• Horizontal distance between a device and the next one at last 20mm.
Check that the cable holder runners do not reduce these distances, in this case fit the cantilever units opposite the panel so that the air can flow vertically on the dissipator without any obstacles.
• Dissipation of device thermic power with effects on installation room temperature.
• Thermal power dissipation with limits on installation room temperature.
• Requires exchange with external air or an air conditioner to transfer dissipated power outside the panel
• maximum limits of voltage and derived power of transients on the line, for which the solid state power unit contains
protective devices (based on the model).
• presence of dispersion current in GTF in non-conducting state (current of a few mA due to RC Snubber circuit to
protect the thyristor).
• Suitable for use on a circuit capable of delivering not more than 100,000A RMS Symmetrical Amperes, 600 Volts maximum when protected by class J fuses rated xxxA. (Refer to the *SCCR fuse protection table this report for the details of the current size fuses for each model)
• Use fuses only.
ATTENTION: The opening of the branch-circuit protective device may be an indication that a fault has been interrupted. To reduce the risk of fire or electric shock, current-carrying parts and other components of the device should be examined and replaced if damaged. If burnout of the device occurs, the complete device must be replaced or equivalent.
GEFRAN S.p.A. assumes no liability for any damage to persons or property deriving from tampering, from incorrect or improper use, or from any use not conforming to the characteristics of the controller and to the instructions in this User Manual.
Conformity TC RU C-IT.AЛ32.B.00422
CSA
Conformity C/CSA/US CoFC no. 70002856
The device are manufactured according with the Community Directives 2011/65/EU (RoHS) 2014/30/EU
(EMC), 2014/35/EU (LVD) in reference to product standard: EN 50581:2012 e EN 60947-4-3:2014
UL
Conformity C/UL/US File no. E243386 vol. 1 sez. 5
Only for models 200A, 250A - 480V and 600V with or without fuse. Model 120A in combination fuse
Only for 480-600V models
This device conforms to TÜV with reference to: EN 60947-4-3
C onneCtions
i nput
/o utput
GTF 150-250A
Low view
WITH option RS485 serial line
Top View
J2
TTL port for PC configuration
Syncronous output for Master/
Slave connection
Alarm output
(solid state relay - HB option)
J3, J4
RJ10 connectors
RS485 serial line
Modbus
Address x 1
Address x 10
Switch for serial line
Input control signal (GND)
Input control signal (+)
Potentiometer output power supply (+5Vdc)
Digital input (PWM input)
Power supply terminal 24Vac/Vdc
Key HB
J1
Power supply /control connector
Fixing screw at heatsink
Green Led (RUN)
Yellow Led (STATUS)
Red Led (Alarm output HB)
Yellow Led (Status digital input)
Led: Green = Thyristor ON
Yellow = Temperature OVER
Identification label
Fixing screw at heatsink
1/L1
LINE connection
3/L2
Reference connection of line voltage
2/T1
LOAD connection
(DIGITAL INPUT)
(Green)
(Yellow)
(Red)
(
(Yellow)
(Green)
Yellow )
(Potentiometer)
INSTALLATION AND OPERATION MANUAL
Side 1 Installation and connection
Electrical connections
Side 2 Technical caracteristics
General caracteristics
Dimensions
Template/Installation
Derating curves
GEFRAN spa via Sebina, 74 - 25050 Provaglio d’Iseo (BS)
Tel. 03098881 - fax 0309839063- Internet: http://www.gefran.com
GTF
POWER CONTROLLER
code 80324G - 06/2018 - ENG
RECOMMENDED WIRE GAUGES
GTF
CURRENT
LEVEL
TERMINAL CABLE WIRE
25A
40A
50A
1/L1, 2/T1,
PE
4 mm 2
10 AWG
10 mm 2
7 AWG
10 mm 2
7 AWG
60A
1/L1, 2/T1,
PE
75A
90A
120A
-
1/L1, 2/T1,
PE
1/L1, 2/T1,
PE
16 mm 2
5 AWG
25 mm 2
3 AWG
35 mm 2
2 AWG
50 mm 2
1/0 AWG
0.25 ... 2.5 mm 2
23...14 AWG
WIRE TERMINAL
Wire terminal / Eye
D. 6mm
Wire terminal / Eye
D. 6mm
Wire terminal / Eye
D. 6mm
Wire terminal / Eye
D. 6mm
Wire terminal tip
TIGHTENING TORQUE /
TOOL
2.5 Nm /
Phillips screwdriver PH2 - PH3
2.5 Nm /
Phillips screwdriver PH2 - PH3
2.5 Nm /
Phillips screwdriver PH2 - PH3
2.5 Nm /
Phillips screwdriver PH2 - PH3
150A
200A
1/L1, 2/T1
1/L1, 2/T1
70 mm
2/0 AWG
95 mm
2
2
4/0 AWG
Wire stripped for 25 mm or with crimped pre-insulated terminal tube CEMBRE PKC70022
Wire stripped for 25 mm or with crimped pre-insulated terminal tube CEMBRE PKC95025
6 Nm /
No. 6 hex head wrench
250A 1/L1, 2/T1
120 mm 2
250 AWG
Wire stripped for 25 mm
-
3/L2
(Ref. Vline)
0.25 ...2.5 mm
23...14 AWG
2 Wire stripped for
8 mm or with tag terminal
Flat-head screwdriver tip
0.6 x 3.5 mm
Note:
Cables must be copper “Stranded Wire” or “Compact-Stranded Wire” type with maximum operating temperature 60/75°C
PE EARTH
TECHNICAL CHARACTERISTICS
Category of use
(Table 2 EN60947-4-3)
Trigger mode
Feedback mode
Max rated voltage
Work voltage range
Non-repetitive voltage
Rated frequency
Rated current AC51 -AC55b non inductive or slightly inductive loads, IR lamps
(@ Tamb = 40°C)
POWER (SOLID STATE)
AC 51 resistive or low inductance loads - AC 55b Infrared lamps
AC 56a: transformer primary in single-phase or open configuration only
PA - Load management by adjusting the firing angle (only configuration singlephase or delta open)
ZC - Zero Crossing with constant cycle time (settable in range 1-200s)
BF - Burst Firing with variable cycle time (GTT) optimized minimum.
HSC - Half Single Cycle corresponds to Burst Firing that includes ON and OFF halfcycles.
Useful for reducing flicker with short-wave IR loads (applied only to single-phase resistive or 3-phase 6-wire open delta loads)
V, V2: Voltage feedback proportional to RMS voltage value on load (useful to compensate possible variations in line voltage)).
I, I2: 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 assigned regardless of load impedance or line voltage variations
480Vac 600Vac 690Vac
90…530Vac
1200Vp
50/60Hz auto-determination
90…660Vac
1600Vp
90…760Vac
1600Vp
25 40
25A 40A
50
50A
60
60A
MODEL GTF
75
75A
90
90A
120
120A
150
150A
200
200A
250
250A
Rated current AC56A permitted trigger modes ZC, BF with DT (Delay Triggering),
PA with sofstart (@ Tamb =40 °C)
Non-repetitive e overcurrent (t=10msec)
I 2 t for melting (t=1…10msec) A 2 s
Critical Dv/dt with output deactivated
Nominal current for short circuit condition
Held nominal voltage of to the impulse
Diagnostics
20A 32A 40A 50A 60A 75A 100A 125A 160A 200A
400A 520A 520A 1150A 1150A 1500A 1500A 5000A 8000A 8000A
450 1800 1800 6600 6600 11200 11200 125000 320000 320000
1000V/μs
5KA
4KV
Detection of short load circuit absence line voltage, HB alarm (partial breakage of load)
DIMENSIONS
GTF 25
GTF 40
GTF50 (Without Fan)
GTF60 (Without Fan)
GTF 75 (Without Fan)
GTF 90 (Without Fan)
GTF 120 (With Fan)
GENERAL DATA
Power supply
Power supply external fan
Signals
Load type and connection
Protection
Work/storage temperature
Relative humidity
Ambient conditions for use
Installation
Installation requirements
GENERAL DATA
GTF 25-120A: 24 Vac 50-60Hz / Vdc ± 25%, max 3VA
GTF 150-250A: 24 Vac 50-60Hz / Vdc ± 25%, max 11VA
(only for GTF120A model) 24 Vdc ± 10%, max 200mA
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
Single phase load / Independent single-phase load in open delta
3-phase load / 3-phase load (star without neutral or closed triangle) with bi-fase control
IP20
0…40°C (refer to dissipation curves) / -20 °C - +70 °C average temperature over a period of 24hour not exceeding 35° C(to EN 60947-4-3 § 7.1.1)
20…85% RH non-condensing indoor use, altitude up to 2000m
DIN bar EN50022 or panel with screws
Installation category II, pollution level 2, double isolation (Only for >120A models)
- Max temperature of air surrounding device 40°C ; for temperature >40°C refer at derating
curves.
- Device type: “UL Open Type”
Weight
GTF 25, 40A
GTF 50, 60A
GTF 75, 90A
GTF 120A
GTF 150, 200, 250A
0,81 Kg
0,79 Kg
1,3 Kg
1,5 Kg
2,5 Kg Max
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.
TEMPLATE / INSTALLATION
L
W
M5
Models
GTF 25-40-50-60A:
GTF 75-90-120A:
GTF 150-200-250A:
L (mm) W(mm)
112
112
287
44
113
42
DERATING CURVES
Models
GTF 25
GTF 60...
Size
I 2 t
390A 2 s
1600A 2 s
3080A 2 s
EXTRARAPID FUSES
Sign
Format
Model
Codc
GTF 75...
GTF 90...
GTF 120...
80A
6600A 2 s
125A
6950A 2 s
125A
6950A 2 s
FUS-080
22x58
FUS-125N
FUS-125N
FWP80A22F
338199
660RF00AT125
338106
660RF00AT125
338106
GTF 150...
GTF 200/250
480V/600V
31500A² s
450A
196000A² s
FUS-200S
FUS-450S s
FUS-400S
*
SCCR RMS SYM UL508 SCCR FUSE PROTECTION TABLE
GTF 200A 600V
GTF 250A 600V
DN00UB60V450L
338932
Class J to up 400A
Power dissipatation@ In
6W
9W
11W
14W
25W
25W
19W
17W
20W
FUSEHOLDERS
Adoption
Acronym code
337134
R/C30A@690V
PFI-22X58
R/C80A@600V
PFI-22X58
R/C80A@600V
PFI-22X58
R/C80A@600V
PF-DIN
R/C400A@1000V
337092
R/C400A@1000V
Graphic symbols
Indicates contents of sections, general instructions, notes, and other points to which the reader’s attention needs to be called.
Indicates a particularly delicate situation that could affect the safety or correct operation of the controller, or an instruction that MUST be followed to prevent hazards.
I Indicates a risk to the user’s safety due to high voltage at the points indicated.
Depth 143 mm
Fastening may be done on DIN guide (EN50022) or with (5MA).
All dimensions are expressed in mm.
Depth 170.4 mm
Attention: respect the minimum distances shown in figure to provide adequate air circulation.
