GFW400...600A
MODULAR POWER
CONTROLLER
INSTALLATION AND OPERATION MANUAL
Side 1
Installation and Connection
Electrical connections
Side 2
Technical-Commercial information
General Information
Dimensions
Fixing/Installation
Derating curves
code 80498A- 05-2019 - ENG
RECOMMENDED WIRE GAUGES
INSTALLATION AND CONNECTION
CONNECTIONS
GEFRAN spa
via Sebina, 74 - 25050 Provaglio d’Iseo (BS)
Tel. 03098881 - fax 0309839063- Internet: http://www.gefran.com
ELECTRICAL CONNECTIONS
+
-
3/L1
5/T1
PORT1
PORT2
PORT3
Top View
Bottom View
4/L2
(Ref. V_Line)
6/T2
(Ref. V_Load)
PE
Ground protection
J5
Connector 3 inputs
external CT (optional)
1/L1
Power line input
(DIN or cable)
J7
V-Load
Connector (optional)
J6
V-Line
Connector
Front View
RUN.........(Green)
ERROR.....(Red)
DI1...........(Yellow)
DI2...........(Yellow)
01.............(Yellow)
02.............(Yellow)
03.............(Yellow)
BUTTON...(Yellow)
J8-J9
PORT1
RS 485 Modbus RTU
2 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
OUT5
OUT6
OUT7
OUT8
J1 - Auxiliary outputs
connector (optional)
J2 - Relay outputs connector
OUT9-OUT10
TA1+
TA1 -
TA2+
TA2 -
TA3+
TA3 -
2/T1
"Load" Output
connection
(DIN or cable)
DB9
Connector
for Keypad
GFW-OP
R
EplaCINg
ThE
I
NTERNal
F
uSE
(O
pTIONal
)
CUT OFF POWER BEFORE AND DURING
FUSE SUBSTITUTION PROCEDURE
- Undo the cover fastening screw (1)
- Remove the cover following the movement indicated by
the arrow (2)
- In this way the fuse is discovered (3)
- Slacken the two bolts fixing the fuse in place with a No.19
spanner (GFW 500/600A) or a No.17 spanner (GFW 400A).
There is no need to remove the bolts, as the fuse is pulled
out of its housing as shown by the arrows (5).
- Insert the new fuse as indicated by the arrows (6)
WARNING: 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 tooth as shown in the figure).
- Fasten the cover by the specific screw in side (1)
GFW
CURRENT
LEVEL
TERMINAL
TYPE CABLE /
SECTION
TYPE RAIL / SECTION
TERMINAL TYPE
CABLE / RAIL
TIGHTENING /
TOOL TORQUE
400 A
1/L1, 2/T1
Single cable
300 mm
2
(600kcmil)
Wire crimped at terminal tube
Cembre A60-M12
N. 1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 442.5 lb.in. (50 N-m) (**) (***)
400 A
1/L1, 2/T1
Double cable
2 x 95 mm
2
(3/0 AWG)
Wire crimped at terminal tube
Cembre A19-M10
N. 2 Bolts M10x25mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
400 A
1/L1, 2/T1
Double cable
2 x 95 mm
2
(3/0 AWG)
Wire stripped for 30mm inserted in
ILSCO AU-350 lug (Accessory)
N. 1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 442.5 lb.in. (50 N-m) (*) see note
400 A
1/L1, 2/T1
Copper rail
(W= width H = height)
W = 40 32 24 mm
H = 2 2 3 mm
Insulated copper rail with terminal
non-insulated for
L= 60-65mm max
N. 1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 442.5 lb.in. (50 N-m)
400 A
PE
Cable 95 mm
2
(3/0 AWG)
Wire crimped at terminal tube
Cembre A19-M10
N. 1 Bolt M10x20mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
500 A
1/L1, 2/T1
Double cable
2 x 120 mm
2
(350 kcmil)
Wire crimped at terminal tube
Cembre A24-M10
N. 2 Bolts M10x25mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
500 A
1/L1, 2/T1
Double cable
2 x 120 mm
2
(350 kcmil)
Wire stripped for 30mm inserted in
ILSCO AU-350 lug (Accessory)
N.1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 442.5 lb.in. (50 N-m) (*) see note
500 A
1/L1, 2/T1
Copper rail
(W= width H = height)
W = 50 40 32 mm
H = 4 4 5 mm
Insulated copper rail with terminal
non-insulated for
L= 60-65mm max
N.1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 442.5 lb.in. (50 N-m)
500 A
PE
Cable 185 mm
2
(350 kcmil)
Wire crimped at terminal tube
Cembre A24-M10
N. 1 Bolt M10x20mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
600 A
1/L1, 2/T1
Double cable
2 x 185 mm
2
(350 kcmil)
Wire crimped at terminal tube
Cembre A37-M10
N. 2 Bolts M10x25mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
600 A
1/L1, 2/T1
Double cable
2 x 185 mm
2
(350 kcmil)
Wire stripped for 30mm inserted in
ILSCO AU-350 lug (Accessory)
N.1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 442.5 lb.in. (50 N-m) (*) see note
600 A
1/L1, 2/T1
Copper rail
(W= width H = height)
W = 50 40 32 mm
H = 4 4 5 mm
Insulated copper rail with terminal
non-insulated for
L= 60-65mm max
N.1 Bolt M12x25mm UNI 5739
hex head wrench n. 18
Pair: 442.5 lb.in. (50 N-m)
600 A
PE
Cable 185 mm
2
(350 kcmil)
Wire crimped at terminal tube
Cembre A37-M10
N. 1 Bolt M10x20mm UNI 5739
hex head wrench n. 17
Pair: 354.0 lb.in. (40 N-m) (***)
400 / 500 /
600 A
J6, J7
Cable 0.25 … 2.5 mm
2
23 …14 AWG
Cable peeled for 8mm or with a tag
terminal
4.425 .... 5.310 lb.in. (0.5 ... 0.6 N-m) /
0.6 x 3.5mm slotted screwdriver
(*) NOTE: Wires on the ILSCO accessory must be tightened with a hex head wrench n. 8. Torque: 275 lb.in. (31 N-m).
(**) NOTE: Use the IP20 grid of ILSCO accessory code F067432.
(***) NOTE: use only UL cable terminals with their stapler
This section contains the instructions needed
for correct installation of GFW modular power
controller 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: Conformity EMC (electromagnetic
compatibility) conformity) in compliance with
Directive 2014/30/EU and following modifications.
Series GFW 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 she- athing.
• 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 GFW semiconductors.
• Connected outside circuits must be doubly isolated.
• To connect analog inputs, strain gauges, linears,
(TC, RTD), you have to:
- physically separate the input cables from those of
the power supply, outputs, and power connections.
- use braided and shielded cables, with sheathing
grounded at a single point.
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 the high reliability of the device,
it is necessary to install it properly inside the panel so
to obtain an adequate thermal exchange.
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 10mm
• Vertical distance between a device and the next one
at last 300mm.
• Horizontal distance between a device and the next
one at last 10mm.
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
without any obstacles.
• Dissipation of device thermal 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 GFW 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.A/132.B.00422
CSA
Conformity C/CSA/US CoFC no. 70002856
The device conforms to European Union Directive 2014/30/EU and 2014/35/EU with reference to standards: EN
60947-4-3:2014.
UL
Conformity C/UL/US file no. E243386 vol. 1 sez. 5
SCCR RMS SYM
100KA / 600V
Short Circuit Current Rating 100KA / 600V according to UL 508
