GFX-4

4 LOOP MODULAR POWER CONTROLLER

Main features
4 independent loop control unit.
Compact, ready to use, equipped also with
fieldbus interface.

Unit consisting of:

• Controller
• 30, 60, 80kW solid state relay
• Current transformers (one or four)
• Fuses-holder (option)
• 4 universal main inputs
• 4 heat/cool independent PID
• 4 main output internally wired to the SSR
• 4 auxiliary analog inputs (option)
• 4 configurable output (option):
relay / logic / TRIAC / continuous
Main application • 2 configurable relay alarm output
• Packaging • 2 digital inputs
• Standard digital communication:
• Extrusion
Modbus RTU
• Thermoforming • Optional Fieldbus communication:
• Injection moulding Profibus DP, CANopen, DeviceNet,
• Textile Modbus RTU, Ethernet Modbus TCP
• Multizone furnaces • DIN rail or panel mounting

PROFILE by a second optional fieldbus MODELS

GFX4 is a four independent loop communication, the by-now indispensable (see table in order code)
controller, designed to manage electrical Profibus DP, CANopen, DeviceNet, 3 different sizes, depending on the
power. Modbus RTU, Ethernet Modbus TCP. electric power managed, are available.
GFX4 is a compact unit bounding The product’s furnished with a standard
different technological elements like: configuration, simple and quickly to GFX4 80
• controller modify. Maximum contemporaneous power up to
• solid state relay The assignment of different functions to 80kW@480V.
• current transformers the outputs is very simple. Each zone could reach up to 19,2 kW.
• fuses-holders (option) This limit could be extend to 23,7 kW
The final result is a cost saving in terms using the “smart power management”
of space and cabling. (not all the zone contemporaneous).
GFX4 consisting of: Nominal current 40A for zone, not
• power management unit contemporary maximum 57A
• analog and digital inputs,
• analog and digital outputs GFX4 60
• standard digital communication Maximum contemporaneous power up to
• integrated solid state relays 60kW@480V.
• fuses-holder (option) Each zone could reach up to 15,3 kW.
Geflex controls autonomously the four Nominal current 32A for zone
loop controllers, furnishing a complete Fuse holder could be provide as an
diagnostics like the loaded current, the option.
control of the zones, the alarms state.
A specific step by step software tool has GFX4 30
been develop in order to assist the Maximum contemporaneous power up to
product configuration based on the 30kW@480V.
different applications. Each zone could reach up to 7,6 kW.
Communication with the outside is of Nominal current 16A for zone
primary importance. Fuse holder could be provide as an
Geflex dialogs with the operator terminals option.
according to the most popular protocols:
from the simple and efficient Modbus to,
INPUTS Outupt 2 state monitor load and trip the HB alarm in
O3 case of current failure or SSR in short
Process analogue Outupt 3 state circuit.
4 universal process input could accept: O4 Detection of short circuit or opening of
thermocouple, thermoresistance, current Outupt 4 state input probe, open loop alarm (LBA),
and tension linear. interrupted load alarm (HB).
The type could be choose by software By default a different meaning is Over temperature alarm
and no external converting device are applicable. The software can be used to define the
required. POWER state of alarm outputs or a preset power
level to be supplied in case of broken
Digital Power is controlled with double SCR in probe.
2 digital input. anti-parallel, zero crossing switching This assures continuity of service in the
The functionality could be selected within principle, with configurable proportional individual zone.
a wide range including setpoint selection, cycle time.
MAN/AUTO, alarm memory reset and Different load connection are available: Tuning
many other. monophase, dualphases, three-phases.
• Self-tuning:
Incorporated CT calculation of PID parameters at system art.
From 1 to 4 CT control each zone and FUSES (OPTION) • Auto-tuning continuous: continuous
the relative alarm control is start up adjustment of PID
(HB..). The fuses are orderable on the GFX4 • Autotuning one-shot: output modulation
30KW and 60kW model. and event-driven automatic PID
Auxiliary analogue (option) Thanks to this, you save time, wiring is parameters re-calculation
4 further analogue inputs are available, simplified, and dimensions in the panel
typically for external current transformer are reduced. Special functions
reading.
• Soft-start: power parcellization time-
PROGRAMMING based
• Software Off: disabling of the control,
OUTPUTS The Geflex modules can be programmed: outputs are turned off
• using GFX-OP • Inputs\outputs: direct management of
Output alarms configurable via software. • using Winstrum tool software inputs/outputs, independently from
• using Industrial PC or PLC. internal firmware
Heating control • Simulation of four independent Geflex
For each zone an heating control units.
internally connected to power unit is FUNCTIONS
present, then no further connections
needed between power unit and Control STANDARD DIGITAL
controller. The Geflex control algorithm works with COMMUNICATION
any type of thermal process.
Cooling control (option) Different control modes are available: The product is furnished with standard
For each zone a cooling control is from a simple ON/OFF control to PID digital communication [PORT 1] used as
present 4 types of outputs are available: single or double acting heat/cool (for GFX4 connection to a HMI or Industrial
relay, logic, triac, continuous. cooling, simply indicate the fluid used). PC.
A current transformer is furnished with Sophisticated and efficient automatic Also by a dedicated connector (10 pins)
TRIAC output. tuning algorithms for control parameters it’s possible to connect the actual range
provide precise process control without of Gefllex.
Alarms the presence of an operator. A second standard digital communication
Two relay output configurable as (PORT 2) configurable by most popular
minimum and maximum alarm are Alarms protocol:
available for each unit. There are 8 alarm assignable to each CANopen
single canal or to all (AND / OR logic) DeviceNet
and configurable as absolute, relative, Profibus DP
LEDS direct, reverse, window, latching or not, Modbus RTU
Eight monitoring led are available in order inhibit at power-on. Ethernet Modbus TCP
to provide diagnostic information. is available as option.
Diagnostics
RN Geflex assures efficient process Net address
RUN stet of the CPU monitoring from a thermal and electrical Assigned by two rotative selectors.
ER point of view, allowing the operator to
Error foresee breakdowns or malfunctions and
DI1 take timely action (for example, in case
DI1 digital input state the temperature safety limit is exceeded,
DI2 broken probe, load fault).
DI2 digital input state The LBA alarm precisely checks the
O1 control loop, while the on-board current
Outupt 1 state transformer (one always present, four
O2 available in option) lets you directly
GENERAL DESCRIPTION

3 4 5 13

2
12

1 7

11

10 8
9
8 1. DIN rail frontal
2. power terminal: screws
3. power terminal
4. ventilation grid (attention NOT obstruct)
5. hook/release device back DIN rail
6. hole for screws
7. microswitchs of configuration
8. standard digital communication
9. rotative selector switch
10. connectors J1, J2, J3, J4
11. fuses-holder (only for 30KW and 60KW models)
12. fuses-holder terminal (F1, F2, F3, F4)
14 13. power terminal (U1, U2, U3, U4)
14. ventilation grid (attention NOT obstruct)

DIMENSIONS - INSTALLATION
19,5

4 101,5
4
35
140

140

132
92,5

140 109,5

147

140 42 4 101,5
19,5

4
35
147

140
111,5

132
92,5

82
182
109,5
195
 Node address: setting by double rotative
DI1, DI2 [digital inputs] selector
Connector: J2 Connector S1 / S2: 2xRJ114/4, RS485 2
wires insul. 1500V
Function Connector S3: 10 pins for flat cable
default not enable (configurable)
Type SERIAL 2 [fieldbus]
PNP, 24Vdc, 8mA (isol. 3500V) Connectors: S4 / S5
TECHNICAL DATA OUTPUTS Function
external fieldbus
INPUTS OUT 1...4 [heating control]
Protocol
IN1...IN4 [process analog inputs] outputs connected to solid state relay Modbus RTU _____115Kbps
Connector: J4 CANopen ________10K...1Mbps
Function Profibus DP ______9,6...12Mbps
Function default heating control (configurable) DeviceNet________125K...500Kbps
default process variable (configurable) Ethernet Modbus TCP 10/100Mbps
Sampling time
120msec the four inputs OUT 5...8 [cooling control] See accessories
Accuracy Connector: J1
0,2% FS ±1 steps at 25°C. (16000 points)
Thermal drift Function MICROSWITCHES
0,005% FS/°C default cooling control (configurable) 8 dip switches are available to select
Type Type wiring mode and different functionalities.
• Thermocouples ITS90: • Relay: NO, max 3A, 250V/30Vdc,
J, K, R, S, T, custom (IEC584-1, CEI EN cosϕ = 1, resistive load
60584-1, 60584-2). • Logic: 24Vdc, 35mA POWER
Internal cold junction compensation with • Continuous:
automatic compensation. • voltage: 0/2...10V, ±10V, max 25mA SSR [integrated power element]
Selectable temperature range: °C/°F short circuit protection
• Thermoresistance: Pt100 DIN 43760 • current: 0/4...20mA, 500Ω max Rated voltage: 480Vac
Max. resistance 20Ω • insulation: 3500V Work voltage range: 24...530Vac
Selectable temperature range: °C/°F • Triac: 230V/4Amp AC51 Non-repetitive voltage: 1200Vp
• Voltage: range 0/12...60mV, Ri > 1MΩ (1A for four) Switching voltage for zero: < 20V
0/0,2…1V, Ri > 1MΩ custom 60mV at 32 (2A for two) Rated frequency: 50/60Hz (self-adjusting)
sections Rated current AC51
• Current: range 0/4...20mA , Ri = 50Ω OUT 9...10 [alarms] GFX-4 30kW: 16Amp
custom 20mA at 32 sections Connector: J1a/J1 GFX-4 60kW: 32Amp
GFX-4 80kW: 57Amp
IN5...IN8 [auxiliary analogue inputs] Function Non-repetitive overcurrent [t=20msec]
Connector: J3 default alarms (configurable) GFX-4 30kW: 400A
GFX-4 60kW: 600A
Function Type GFX-4 80kW: 1150A
default analog inputs reading Relay: NO, max 5A, /30Vdc, cosϕ = 1 I2t for melt [t=1...10msec]
Sampling time GFX-4 30kW: 645A2s
480msec for TC, voltage GFX-4 60kW: 1010A2s
Accuracy LEDS GFX-4 80kW: 6600A2s
1% FS ±1 steps at 25°C. Dv/dt critical with deactivated output:
Type RN . . . . . .RUN state of the CPU 1000V/µsec
• Thermocouple ITS90: ER . . . . . .error Rated insulation voltage In/Out:
J, K, R, S, T, custom (IEC584-1, CEI EN DI1 . . . . . .DI1 digital input state 4000V
60584-1, 60584-2). DI2 . . . . . .DI2 digital input state
Internal cold junction compensation with O1 . . . . . .Out.1 main input state
automatic compensation. O2 . . . . . .Out.2 main input state GENERAL FEATURES
• Voltage: O3 . . . . . .Out.3 main input state
range 0/12...60mV, Ri > 1MΩ O4 . . . . . .Out.4 main input state Power supply:
24Vdc ±25%, max 8VA
IN9...IN12 [internal CT input] Protection class:
Connector: internal connection IP20
COMMUNICATION PORTS Working temperature range:
Function 0...50°C (see dissipation curves)
default internal CT reading PORT 1 [local bus] Storage temperature range:
Sampling time Connectors: S1 / S2 / S3 -20...+70°C
60msec for CT Relative humidity:
Accuracy Function: local bus 20...85% UR non-condensing
1% FS ±1 steps at 25°C. Protocol: Modbus RTU Installation:
Type Baud Rate: 115Kbps (default) EN50022 DIN rail or panel by screw
internal CT: 50mAac, 50/60Hz, Ri = 10Ω setting 1200...115Kbps Dimensions:
ELECTRICAL CONNECTIONS

Triac Logic/continuous Relay

c (OUT 5...8) 1

Load 1 OUT 5 no

Load 2 OUT 6 no

Load 3 OUT 7 no

Load 4 no
OUT 8
J1 4 +VI
c 3 Tx/Rx-
6
2 Tx/Rx+
S1
OUT 9
no 1 GNDI

c J1a 4 +VI
3 Tx/Rx-
OUT 10
no 9
9
2 Tx/Rx+ S2
1 GNDI Port 1
1
Green
POWER SUPPLY
18...32Vdc Red J2 S3
+24Vdc
Yellow
7
Yellow
1
Yellow
Yellow
IN 5 S4
Yellow
IN 6
J3
Yellow
IN 7 Port 2
IN 8 12

1
IN 1
S5

IN 2

J4
IN 3

IN 4
12

power
Model without fuses-holder Model with fuses-holder
F1 F2 F3 F4

F1 F2 F3 F4 U1 U2 U3 U4

U1 U2 U3 U4

Model 30kW 60kW 80kW

max current 16A 32A (30A)* 57A (40A)*

0,2 - 6mm2 24-10AWG 0,2 - 6mm2 24-10AWG 0,5 - 16mm2 20-6AWG

rigid

0,2 - 4mm2 24-10AWG 0,2 - 4mm2 24-10AWG 0,5 - 10mm2 20-7AWG

flexible
0,25 - 4mm2 23-10AWG 0,25 - 4mm2 23-10AWG 0,5 - 10mm2 20-7AWG

0,25 - 4mm2 23-10AWG 0,25 - 4mm2 23-10AWG 0,5 - 10mm2 20-7AWG

0,5 - 0,6Nm 0,5 - 0,6Nm 1,2 - 1,5Nm

* UL certification
 ORDER CODE

Current (Amp) Voltage (Vac) Power (kW)

Model max range nominal working total single max for
GFX4 for channel contemporary channel single channel

(4x16x110) (16x110) (1x16x110)

110
7 1,7 1,7
(4x16x230) (16x230) (1x16x230)
230
30 14,7 3,6 3,6
16 24...530 480
(4x16A) (4x16x400) (16x400) (16x400
400
25,6 6,4 6,4
(4x16x480) (16x480) (1x16x480)
480
30,7 7,6 7,6
(4x32x110) (32x110) (32x110)
110
14 3,5 3,5
(4x32x230) (32x230) (1x32x230)
60 230
29,4 7,3 7,3
(4x32A) 32 (30)* 24...530 480
(4x30A)* (4x32x400) (32x400) (1x32x400)
400
51,2 12,8 12,8
(4x32x480) (32x480) (1x32x480)
480
61,4 15,3 15,3
(4x40x110) (40x110) (1x57x110)
110
17,6 4,4 62,7
(4x40x230) (40x230) (1x57x230)
230
80 36,8 9,2 13,1
40* 57 24...530 480
(4x40A) (4x40x400) (40x400) (1x57x400)
400
64 16 22,8
(4x40x480) (40x480) (1x57x480)
480
76,8 19,2 27,3
* UL Certificate
GFX4

NOMINAL POWER FIELDBUS

30KW 30 0 Absent

M Modbus RTU
60KW 60
P Profibus DP
80KW 80
C CANopen

C1 Euromap 66

D DeviceNet
AUXILIARY OUTPUTS
E Ethernet Modbus TCP
Absent 0
E1 Ethernet IP
Relay R

Logic D FUSES

Continuous C 0 Absent

Triac T F fuses-holder + fuses extrarapid (*)

(*) Available only for 30, 60kW power.

AUXILIARY INPUTS

1 1 Current Transformer

2 4 Current Transformers

1 Current Transformer
3
+ 4 Linear inputs
4 Current Transformers
4
+ 4 Linear inputs

GEFRAN spa reserves the right to make aesthetic or functional changes at any time and without notice.

GEFRAN spa via Sebina, 74 - 25050 Provaglio d’Iseo (BS)

Tel. 03098881 - fax 0309839063
Internet: http://www.gefran.com DTS_GFX4_1008_ENG