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gefran GFW 400A, Installation And Operation Manual

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6

80999D_MHW_GFW 400-600A_07-2020

_ENG

GFW-400/600A INSULATION DIAGRAM

INPUTS

POWER SUPPL

Y

CPU

POR

T

 1

POR

T

 2

TA INPUT (I_load)

TA1, T

A2, T

A3

4KV

Main Pr

ocessor

EEpr

om

RAM

LEDs

OUTPUTS

OUT9, 10

Fieldbus MODBUS  RS485

Ether

net Modbus TCP

Ether

net-IP

Ether

cat

CanOpen

Pr

ofibus                     

Supply  18 …32V

MODBus RS485

ANALOG COMMAND INPUT

DIGIT

AL INPUTI

DI1, DI2, DI3, DI4

TV INPUT (V_line)

TV1, TV2, TV3

OUT 

5,6,7,8,

Analog 

/ 

Digital                       

2KV                                             

±

5v

1KV

 

DC / DC

5v

1KV

 

DC / DC

Connected to 24V

Connected to5V (POR

T1)

Connected to (90..690V)

Connected to 5V CPU

Legend

max 230 V

ac

1KV

500V

1KV                                             

1KV

max 690 V

ac SSR

SSR1, SSR2, SSR3 

POWER CONTROLLER

OUT 1,2,3 

4KV 

                                    

                                  

OUT 9, 10 RELÈ

Summary of Contents for GFW 400A

Page 1: ...gh voltage at the points indicated 1 PRELIMINARY INSTRUCTIONS 2 1 1 Profile 2 1 2 General Description 2 1 3 Preliminary instructions 3 2 INSTALLATION AND CONNECTION 4 2 1 Electrical power supply 4 2 2 Notes on electrical safety and electromagnetic compatibility 4 2 3 Recommendations for Correct Installation for purposes of EMC 4 2 4 Dimensions 7 2 5 Template dimensions 8 2 6 Installation 8 2 7 Sho...

Page 2: ...cuit Alarm for load in short circuit or overcurrent Alarm for interrupted internal fuse Voltage Diagnostics Alarm for absence of phase Signal for incorrect rotation of 3 phases for triphase applications Alarm for triphase line unbalance Temperature Diagnostics Measurement of power module temperature Alarm for over temperature of power module Measurement of power terminals temperature Alarm for ove...

Page 3: ...rrors 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 GFW 1PH 400 690 0 0 1 Model Nominal current Nominal voltage Contol option Current limit Output sAux 4 Relay etc See paragraph Dimensions and mounting before installing the GFW on the ma...

Page 4: ...e 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 controller...

Page 5: ...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 1 kV I O signal line Surge immunity EN 61000 4 4 5 Power line line...

Page 6: ...thernet Modbus TCP Ethernet IP Ethercat CanOpen Profibus Supply 18 32V MODBus RS485 ANALOG COMMAND INPUT DIGITAL INPUTI DI1 DI2 DI3 DI4 TV INPUT V_line TV1 TV2 TV3 OUT 5 6 7 8 Analog Digital 2KV 5v 1KV DC DC 5v 1KV DC DC Connected to 24V Connected to5V PORT1 Connected to 90 690V Connected to 5V CPU Legend max 230 Vac 1KV 500V 1KV 1KV max 690 Vac SSR SSR1 SSR2 SSR3 POWER CONTROLLER OUT 1 2 3 4KV OU...

Page 7: ...7 80999D_MHW_GFW 400 600A_07 2020_ENG 2 4 Dimensions SINGLE PHASE GFW GFW DUAL PHASE GFW THREE PHASE Figure 1 ...

Page 8: ...espect the minimum distances shown in figure 3 to provide adequate air circulation Figure 2 Figure 3 65 0 339 0 65 0 M5 X4 FORI 5 2 339 0 65 0 M5 X8 FORI 5 2 31 5 65 0 65 0 65 0 339 0 65 0 M5 X12 FORI 5 2 31 5 65 0 31 5 65 0 15 8 15 8 15 8 6 0 6 0 6 0 GFW MASTER GFW BI PHASE GFW THREE PHASE ...

Page 9: ... recommend the use of extra rapid fuses as in table EXTRARAPID FUSES ATTENZIONE 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 replace...

Page 10: ... input connector 7 Connector for GFW OP keypad 8 24 V fan power supply output connector 9 Load terminal pre split protection grid 10 Cover on internal fuse protection and Line Load connections 11 Line terminal pre split protection grid 12 V load measurement connector 13 V line measurement connector 14 3 way external TA input connector 15 Port2 Fieldbus connectors and led 16 Operating status led 17...

Page 11: ...ower supply connector from the fan b Use a crosshead screwdriver to unscrew the two screws holding the fan in place see drawing c Extract the fan complete with its protective grid and inspect d Clean or replace the fan CAUTION before putting the fan back into the product make sure that the arrow showing the direction of the air flow on the fan is pointing toward the dissipater e Insert the fan com...

Page 12: ...ve the bolts as the fuse is pulled out of its housing as shown by the arrows 5 Insert the new fuse as shown by the arrows 6 CAUTION the washer must be between the bolt and the copper strap NOT under the fuse Tighten the two nuts with a No 19 spanner GFW 500 600A or a No 17 spanner GFW 400A to a torque of 12 Nm Put the cover back in place pinning down the top part first be careful to hook it on the...

Page 13: ...porting card 6 Check that the card is inserted correctly d Put the CPU cover 4 back in place and fix it in place by tightening the screws 3 e Use the new front piece 2 supplied with the Fieldbus card or open the pre fractured parts present on the product s original front piece and fix it in place by tightening the screws 1 WARNING Use ESD guards to avoid to damage the internal HW with electrostati...

Page 14: ...50 Kcmil Wire stripped for 30mm inserted in ILSCO AU 350 lug Accessory N 1 Bolt M12x25 mm UNI 5739 hex head wrench n 18 Pair 50 Nm 500 A 1 L1 2 T1 Copper rail W width H height W 40 32 24 mm H 3 4 5 mm Insulated copper rail with terminal non insulated for L 60 65 mm max N 1 Bolt M12x25 mm UNI 5739 hex head wrench n 18 Pair 50 Nm 500 A PE Cable 120 mm2 250 Kcmil Wire crimped at terminal tube Cembre ...

Page 15: ...15 80999D_MHW_GFW 400 600A_07 2020_ENG ...

Page 16: ...figuration LED ER red LED Ox yellow both flashing HB alarm or POWER_FAIL in zone x All LEDs flashing rapidly ROTATION123 alarm only for threephase configuration All LEDs flashing rapidly except LED DI1 jumper configuration not provided All LEDs flashing rapidly except LED DI2 30 _UNBALANCED_ERROR alarm only for threephase configuration All LEDs flashing rapidly except LED O1 SHORT_CIRCUIT_CURRENT ...

Page 17: ...us RTU2 RJ11 connector Dip Switch serial line INA1 GND EARTH INA2 INA3 GND Out 5V potentiometer J4 3 analog inputs connector Magnetic area keypad fixing GFW OP HB Button DipSwitch Load configuration RotarySwitch Modbus address FIELDBUS optional 8 LED STATUS configurable 24Vdc supply GND EARTH INDIG1 INDIG2 INDIG3 INDIG4 GND J3 Power connector and Digital Inputs 24V C OUT9 NC NO C OUT10 NC NO COM O...

Page 18: ... 0 4 20mA max 500Ω Figure 12 Wiring diagram for logical analogue outputs LOAD LOAD LOAD LOAD 1 5 4 3 2 O5 O6 O7 O8 Com 5 8 V I Table 7 PIN Name Decription Logic Analogue 1 Com 5 8 Outputs common 2 O5 Output 5 3 O6 Output 6 4 O7 Output 7 5 O8 Output 8 n c RELAY OUTPUTS 5 8 option R Outputs Out 5 8 relay Ir 3A max NO V 250V 30Vdc cosφ 1 I 12A max Figure 13 Connection scheme for relay outputs LOAD O8...

Page 19: ...relay 5A max Relay with exchange contact C NC NO V 250V 30Vdc cosφ 1 I 5A max Figure 15 Connection scheme for relay outputs Table 10 PIN Name Description 1 C Out 9 Out 9 Common contact 2 NC Out 9 Out 9 Normally closed contact 3 NO Out 9 Out 9 Normally open contact 4 C Out 10 Out 10 Common contact 5 NC Out 10 Out 10 Normally closed contact 6 NO Out 10 Out 10 Normally open contact ...

Page 20: ...iption 1 24Vdc 24 Vdc supply 2 GND 3 Earth Earth EMC 4 INDIG1 Digital input 1 5 32Vdc configurable NPN PNP 5 INDIG2 Digital input 2 5 32Vdc configurable NPN PNP 6 INDIG3 Digital input 3 5 32Vdc configurable NPN PNP 7 INDIG4 Digital input 4 5 32Vdc configurable NPN PNP 8 GND GND common Figure 17 Connection scheme Wiring diagram with PNP inputs Wiring diagram with NPN inputs ...

Page 21: ... 14AWG 0 25 2 5mm2 23 14AWG Table 14 PIN Name Description 1 5V_POT Output 5V potentiometer s power supply max 30 mA 2 INA1 Analogue command input INA1 3 GND GND command signal 4 EARTH Earth EMC 5 INA2 Analogue command input INA2 6 INA3 Analogue command input INA3 7 GND GND command signal Figure 19 Connection scheme ...

Page 22: ...ptional Figure 20 Connector J5 1 2 3 4 5 6 Table 15 0 25 2 5mm2 23 14AWG 0 25 2 5mm2 23 14AWG Figure 21 Connection scheme Table 16 PIN Name Description 1 TA1 External TA1 input max 5 A rms 2 TA1 3 TA2 External TA2 input max 5 A rms 4 TA2 5 TA3 External TA3 input max 5 A rms 6 TA3 ...

Page 23: ...F ON OFF OFF OFF ON Three Independent single phase load in open delta x x x ON ON OFF OFF OFF ON 3 phase load open delta star load with neutral x x x ON ON ON OFF OFF ON 3 phase load closed delta x x x ON OFF OFF ON OFF ON 3 phase star load without neutral x x x ON OFF OFF OFF OFF ON 3 phase star load without neutral with 2 phase command x x ON OFF ON OFF OFF ON 3 phase load closed delta with 2 ph...

Page 24: ...J10 4 4 pin Nr Pin Name Decription Note 4 3 2 1 1 GND1 Insert the RS485 line termination in the last device on the Modbus line see dipswitches Connect the GND signal between Modbus devices with a line distance 100 m 2 Tx Rx Data reception transmission A 3 Tx Rx Data reception transmission B 4 V reserved Cable type flat telephone cable for pin 4 4 conductor 28AWG ...

Page 25: ... termination Table 20 Connector S4 S5 RJ10 4 4 pin Nr Pin Name Decription Note 4 3 2 1 1 GND1 Insert the line termination in the last device on the Modbus line Connect the GND signal between Modbus devices with a line distance 100 m 2 Tx Rx Data reception transmission A 3 Tx Rx Data reception transmission B 4 V reserved Cable type flat telephone cable for pin 4 4 conductor 28AWG ...

Page 26: ...A 3 Tx Rx Data reception transmission B 4 V reserved Cable type flat telephone cable for pin 4 4 conductor 28AWG Table 22 Connector S5 D SUB 9 pins male Nr Pin Name Decription Note 1 2 3 4 5 6 7 8 9 1 SHIELD EMC protection Connect the terminal resistances as shown in the figure 2 M24V Output voltage 24V 3 RxD TxD P Data reception transmission 390 W Data line Data line 390 W 220 W RxD TxD P 3 RxD T...

Page 27: ...Cable type flat telephone cable for pin 4 4 conductor 28AWG Table 24 Connector S5 D SUB 9 pins female Nr Pin Name Decription Note 5 4 3 2 1 9 8 7 6 1 Reserved Connect the terminal resistances as shown in the figure 2 CAN_L CAN_L bus line domination low 3 CAN_GND CAN Ground CAN_L CAN_H 120 Ω 120 Ω node 1 node n CAN Bus Line 4 Reserved 5 CAN_SHLD Optional CAN Shield 6 GND Optional Ground 7 CAN_H CAN...

Page 28: ... 2 1 1 GND1 Connect the GND signal between Modbus devices with a line distance 100 m 2 Tx Rx Data reception transmission A 3 Tx Rx Data reception transmission B 4 V reserved Cable type Flat telephone cable for pin 4 4 conductor 28AWG Table 26 Connector S5 RJ45 Nr Pin Name Decription Note 8 1 1 TX Data transmission 2 TX Data transmission 3 RX Data reception 4 n c 5 n c 6 RX Data reception 7 n c 8 n...

Page 29: ...pin Nr Pin Name Decription Note 4 3 2 1 1 GND1 Connect the GND signal between Modbus devices with a line distance 100 m 2 Tx Rx Data reception transmission A 3 Tx Rx Data reception transmission B 4 V reserved Cable type flat telephone cable for pin 4 4 conductor 28AWG Table 28 Connector S5 RJ45 Nr Pin Name Decription Note 8 1 1 TX Data transmission 2 TX Data transmission 3 RX Data reception 4 n c ...

Page 30: ...ment input option Figure 30 GFW connection example for 1 single phase transformer load GFW Master Dip Switches Configuration Dip 1 Dip 2 Dip 3 Dip 4 Dip 5 OFF OFF OFF OFF ON V phase voltage line L1 line L2 N P power of each single phase load Vload voltage on secondary load Id current in primary Is current in secondary φ transformer output typical 0 9 pif resistive load cosφ 1 FIRING MODE ZC PA BF ...

Page 31: ...two loads GFW Master Dip Switches Configuration Dip 1 Dip 2 Dip 3 Dip 4 Dip 5 OFF OFF OFF OFF OFF V line voltage P power of each single phase load Id load current if resistive load cosφ 1 FIRING MODE ZC BF HSC PA HB DIAGNOSTIC AVAILABLE Partial and total load failure pof each single leg Fast Fuse Needed only for controller with option Fuse 0 GG Fast Fuse See Fuse section IMPORTANT Take care to con...

Page 32: ...r output typical 0 9 pif resistive load cosφ 1 FIRING MODE ZC BF HB DIAGNOSTIC AVAILABLE Total load failure Fast Fuse Needed only for controller with option Fuse 0 GG Fast Fuse See Fuse section IMPORTANT Take care to connect terminals 1 L1 and 3 L1 to the same phase 1 L1 2 T1 GFW M 1 L1 2 T1 GFW E1 L2 L3 L1 FUSE GG R Load R Load R Load PE 4 L2 6 T2 5 T1 4 L2 6 T2 5 T1 3 L1 3 L1 J6 J6 FUSE Y Y 1 L1...

Page 33: ...2 L3 L1 FUSE GG PE FUSE GG 4 L2 6 T2 5 T1 4 L2 6 T2 5 T1 J7 3 L1 3 L1 J7 J6 J6 to TA2 to TA1 TA1 TA2 imput J5 FUSE Y Δ Y Δ Y Δ Y Δ R Load R Load TA2 TA1 to J5 R Load Current Transformers GFW E GFW M L1 L2 L3 V 1 L1 2 T1 1 L1 2 T1 R R R Y Δ Y Δ ƞ 3 V cosφ Id P ƞ 3 Vload cosφ Is P Vload Is Id Control option 0 Control option 3 Vload input Control option 4 Vload input and external TA input Symmetrical...

Page 34: ...and total load breakage for each individual branch for PA mode HB diagnostics active with P 30 Fast Fuse Needed only for controller with option Fuse 0 GG Fast Fuse See Fuse section 1 L1 2 T1 GFW M 1 L1 2 T1 GFW E1 1 L1 2 T1 GFW E2 L2 L3 L1 FUSE FUSE GG PE 4 L2 6 T2 5 T1 4 L2 6 T2 5 T1 4 L2 6 T2 5 T1 J6 3 L1 3 L1 3 L1 J6 J6 R Load Y Δ Y Δ 1 L1 2 T1 GFW M 1 L1 2 T1 GFW E1 1 L1 2 T1 GFW E2 L2 L3 L1 F...

Page 35: ...tial and total load breakage for each individual branch for PA mode HB diagnostics active with P 30 Fast Fuse Needed only for controller with option Fuse 0 GG Fast Fuse See Fuse section IMPORTANT Take care to connect terminals 1 L1 and 3 L1 to the same phase 1 L1 2 T1 GFW M 1 L1 2 T1 GFW E1 1 L1 2 T1 GFW E2 L2 L3 L1 FUSE FUSE GG R Load R Load R Load PE 4 L2 6 T2 5 T1 4 L2 6 T2 5 T1 4 L2 J6 3 L1 3 ...

Page 36: ...ection IMPORTANT Take care to connect terminals 1 L1 and 3 L1 to the same phase Only required with Vload measurement input option Figure 41 GFW connection example for 1 3 phase load open delta GFW Master Dip Switches Configuration Dip 1 Dip 2 Dip 3 Dip 4 Dip 5 ON ON OFF OFF OFF V line voltage P power of each single phase load Id load current if resistive load cosφ 1 FIRING MODE ZC BF HSC PA HB DIA...

Page 37: ...asurement input option Figure 43 Example of GFW3 PH wiring for 3 indipendent single phase loads It is possible to connect three single phase loads also to three different line voltages between line to line or line to neutral It is possible to manage by Fieldbus different power values for each one of the three loads GFW Master Dip Switches Configuration Dip 1 Dip 2 Dip 3 Dip 4 Dip 5 OFF OFF OFF OFF...

Page 38: ...number of operating cycles with zero crossing firing mode modulation through variation of the phase angle ZERO CROSSING MODE A type of operation that eliminates EMC interference This mode manages load power through a series of ON operating cycles rather than OFF operating cycles ZC constant cycle time Tc 1 sec settable from 1 to 200 sec Cycle time is divided into a series of conduction and non con...

Page 39: ...hese loads to limit operating current with low power it is useful to set a minimum power limit for example Lo P 10 ref GFX4 IR operation guide NB This mode is NOT allowed with inductive loads transformers It is used with resistive loads in singlephase star with neutral or open delta configuration Figure 46 Advanced single cycle Example of operation in HSC mode with power at 33 and 66 Phase angle P...

Page 40: ...n the load shut off time settable is exceeded the ramp is reactivated at the next power on Figure 48 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 B...

Page 41: ...sient with Over Current Transient without 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 51 Example of phase ramp to fire a transformer in PA mode Example of firing with Delay Triggering of a transformer in ZC mode Comparison of method to fire a ...

Page 42: ... 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 GFW digital input INDIG1 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 NOTE for inputs INDIG2 and INDIG3 the maximum PWM fre...

Page 43: ... order code a Fieldbus serial Serial 2 with one of the following protocols Modbus RTU Profibus DP CANopen DeviceNet e Ethernet Modbus TCP The MODBUS RTU port 1 has the following factory settings default Parameter Default Range ID 1 1 99 BaudRate 19 2Kbit s 1200 115kbit s Parity None parity odd parity none StopBits 1 DataBits 8 The following procedures are indispensable for the Modbus protocol For ...

Page 44: ...the network to serial 1 and to the supervision terminal 2 Set the rotary switch on the GFW modules to be installed or on all modules present in case of first installation toposition 0 0 3 Check that the green STATUS LEDs flash at highfrequency 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 green L1 STATU...

Page 45: ...duction angle 90 Function voltage measurement RMS on load Load voltage read Accuracy RMS voltage measurement on load 1 f s with VLOAD option measurement Otherwise the value is calculated from the values of line voltage and power delivered accuracy 2 F S Inputs measuring current from external TAs No 3 inputs optional Input impedance 16 mohm Input dynamic 0 5 Arms Accuracy 1 f s Thermal drift for me...

Page 46: ...arm Function Function Configurable default alarms Relay Contact in exchange C NO NC 5A 250V 30Vdc cosφ 1 COMMUNICATIONS PORTS PORT GFW OP Function Serial comunication for KB ADL terminal to display parameter programming PORT1 always present Function Function Local serial communication Protocol ModBus RTU Baudrate Settable 1200 115200 default 19 2Kbit s Node address Node address Settable with rotar...

Page 47: ...c or 690V Operating voltage range 90 530Vac models 480V 90 660Vac models 600V 90 760Vac models 690V Non repetitive voltage 1200Vp models480V 1600Vp models 600V 690V Rated frequency 50 60Hz auto determination Critical Dv dt with output deactivated 1000V µsec Nominal impulse voltage 4KV Nominal current for short circuit condition 5KA Protection RC extrarapid fuses for SCR Rated current AC51 non indu...

Page 48: ...H 1 single phase load with one Master units and one Expansion GFW 2PH 2 single phase loads in ZC and BF trigger mode only 1 phase load closed delta controlled on two phases 1 phase load star without neutral controlled on two phases with one Maste units and two Expansions GFW 3PH 3 single phase loads 3 independent single phase loads open delta 1 phase load open delta 1 phase load closed delta 1 pha...

Page 49: ...re 53 100 200 300 400 500 600 700 50 60 T C I A 0 GFW 400 500 600A Model with internal fuse GFW 1PH GFW 2PH GFW 3PH Weight GFW 400 8 Kg 15 5 Kg 22 5 Kg GFW 500 600 11 Kg 21 Kg 31 Kg Packaging dimension GFW 1PH 420 x 480 x 250 mm GFW 2PH o GFW 3PH 420 x 520 x 510 mm ...

Page 50: ...ELDBUS Port 2 opt 0 Absent M Modbus RTU P Profibus DP C CANopen E Ethernet Modbus TCP E1 Ethernet IP E2 EtherCAT E4 PROFINET E6 Profinet as for technical specific 2016 Stack 3 12 05 E7 EtherCAT as for technical specific 2016 Stack 4 7 0 3 E8 Ethernet IP ODVA Certification C T 16 Auxiliary Output optional 0 Absent R 4 Relays D 4 Digital outputs C 4 Direct analogue outputs T 4 Triac outputs W 3 anal...

Page 51: ...F_eXK 2 0 0 Cod F049095 The human machine interface HMI is simple intuitive and very practical thanks to the optional GFW OP programming keyboard Permits reading and or writing of all pre GFW control parameters Connected with 9 pin D SUB connector and housed in the front panel of the GFW M by means of a magnetic plate Alphameric display 5 lines x 21 characters Keys to display variable and set para...

Page 52: ...160 60 W 6 3 1 Fuse GG 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 GEFRAN spa via Sebina 74 25050 Provaglio d Iseo...

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