GEFLEX GFX-M1 / GFX-S1 /GFX-E1

MODULAR POWER CONTROLLER FOR TEMPERATURE CONTROLLED ZONES

Main features
Three versions:
MASTER - independent temperature
control and communication unit
SLAVE - independent temperature
control unit
EXPANSION - for three-phase loads
SSR (Solid State Relay) zero crossing
Rated voltage:
480Vac rms, 50-50Hz
Rated current (AC1): 25A, 40A,
60A, 75A, 90A, 120A
Protection: IP20
Installation: DIN bar and panel
Universal temperature input,
accuracy 0.2%
Configurable digital input
Main applications Logic output or cooling relay
Load current detection with integrated CT
Plastic extruders Heat/cool PID, selection of cooling fluid,
Plastic injection presses self-tuning,auto-tuning, soft-start
Blowers 4 generic alarms, LBA and HB alarms
Plastic and rubber processing 2 configurable relay outputs
machines Field bus for Master:
Wrapping machines std: Modbus RTU with Serial RS485
Packaging machines optically
Thermal processes with opt: PROFIBUSDP, CANopen,
electric heating DeviceNet

PROFILE command to two other expansion units Up to 14 different control modes are
An innovative, integrated system to con- equipped with SSR module only. available: from simple ON/OFF control
trol power and temperature, designed for The power control has double SCR in to single or double action heat/cool PID;
industrial electric heating processes. The antiparallel, zero crossing switching prin- for cooling, simply indicate the fluid being
system architecture is optimized for tem- ciple, with configurable proportional cycle used.
perature control of multizone plants. It con- time.The electrical connections for power Sophisticated and efficient algorithms for
sists of a control unit, i.e., the PID micropro- and control are completely separate to automatic tuning of control parameters
cessor controller plus load control device increase electrical safety and reduce provide precise process control without
(AT and VT), and a power module (SSR) electromagnetic interference. user intervention.
with aluminum heat sink. The system is Mechanics Outputs and digital input
compact and easy to install and use. The mechanical elements have been The instrument can have up to 3 outputs:

Models and communication carefully designed and tested for maxi- a cooling (3A, 250V) or logic (24Vdc,
The system has high communication mum ease of installation and to guarantee 35mA) relay and two optional alarm relay
capacity and interfaces without limitation high resistance to vibration and thermal outputs (3A, 250V).
with the automation environment. stress. The outputs are freely configurable via
Three standard protocols are available: software.
Diagnostic LEDs
Modbus RTU, Profibus DP and CANopen By means of internal bus, each slave
The lower section has 3 LEDs that indi-
implemented in the Geflex master, which can activate the two relay outputs on the
cate the operating state of the field bus,
in turn communicates with up to nine master following alarm conditions to
temperature sensor errors, and the con-
Geflex slaves by means of an internal create electrical clearance or block signals
ducting state of the power unit.
bus.Every Geflex can tune to the network set to assure safe operation of technologi-
communication speed (baud) with a self- Temperature input cal systems.
learning sequence. In addition to con- The temperature input is universal and can This further reduces electromechanical
necting to PLCs, terminals, and PCs, the be connected to a wide variety of signal wiring.
master is able to control a control loop. types: thermocouples, resistance thermo- At the logic level, there are 4 generic
meters, input from 4...20mA transmitters, alarms configurable as: absolute, devia-
Power definable only by software, without the tion, direct, reverse, window, in latching or
Five current levels are offered: 25, 40, 60, need for external adapter shunts. non-latching mode, disabled at power-up.
75, 90 and 120A, all with rated voltage of Accuracy of 0.2% guarantees excellent With the isolated digital input always
480V, single phase. control of the heat process. available, you can select one of the two
To control three-phase loads, the system
PID pre-settable set points select Manual-
uses a connection with 3 Geflex units: a
The control algorithm adapts to every type Automatic mode, reset the alarms memo-
master unit that performs the PID control
of heat process. ry, or enable the hold function.
and transmits (via internal bus) the power
Safety, diagnostics Resolution: < 2V for range 60mV. Application: cooling, alarm.
At the logic level, there are 4 completely Input filter: 0...20.0sec. - Continuous
configurable generic alarms. Zero offset adjustable in range: 0...10V; 0/4...20mA
Efficient diagnosis of the control loop pre- -999...+999 scale points.
Application: cooling, alarms.
vents breakdowns and lets the user take
Main input
timely action (for example, in case of bro- Digital communication, Field bus
Thermocouple, resistance thermometer,
ken probe or load failure). Asynchronous serial transmission.
Linear.
The LBA alarm carefully controls the Std. protocol: MODBUSRTURS485 2
Application: process variable.
control loop, while the on-board current Thermocouples: wires, 1200...19200 baud.
transformer lets you directly monitor the ITS90: J, K, R, S, T, B, E, N, U, G, D, C, Optional protocols: CANOPEN 10K...1M bit/
load and activate the HB alarm in case of custom. sec, PROFIBUSDP9,6...12Mbit/sec.
current failure or SSR in short. Cold junction compensation: internal, with
In addition, the on-board voltage transfor- automatic compensation. Safety
mer lets the user monitor line voltage, Resistance thermometer: Detection of short circuit or opening of input
power, and energy, with important bene- Pt100 DIN 43710, J Pt100, custom. probe, open loop alarm (LBA), load fault
fits for safety and plant efficiency. Linears/Transmitters: alarm (HB), overheat SCR.
Software can be used to define the state range 0...60mV, 0...20mA, 0...1Vdc Process control functions
of the alarm outputs or a preset power (configurable within limits).
level to be supplied in case of a broken Possible 32 segment custom linearization. Control
probe, thereby assuring continuous servi- PID, PI, PD, P, On/Off, heat, cool, heat + cool
ce of the individual module. Load control with fluid selection.
LEDs signal any fault in real time, and TA, TV internal: Manual/Automatic: Bumpless or with manual
powerful diagnostics is available via serial. Ammeter: forcing of output.
A simple command from the digital input range 0...25, 40, 60, 75, 90, 120Aac
Applicazioni: controllo corrente assorbita dal Tuning
deactivates the control zone by software - Self-tuning: calculation of PID parameters at
shutdown of the instrument. carico.
Tensione di linea: system start.
Programming campo 0...480Vac. - Auto-tuning: continuous adjustment of PID
The supervision system can interrogate Applications: control of current absorbed by values.
each individual slave to obtain informa- load. Special functions
tion, to program, or configure the instru- Soft-start, power limitation, software
ment. Digital input shutdown.
For even simpler configuration, a pro- PNP 24V, 8mA (isol. 3500V)
Alarms
gramming kit (from notebook PC or palm Applications: Man/Auto, Loc/Rem, Hold,
Up to 4:
Reset alarms, select setpoint, shut down
PC) is available, composed of an IRDA absolute, deviation, symmetric, direct, rever-
software.
interface unit and WINSTRUM (a guided se, Latching and non, LBA, HB.
program for Windows environment - see Outputs Reference: PV, SP, aux input (for HB).
technical sheet).
Max 3 Relays / 1 Logic + 2 Relays. Multiset
Double setpoint with gradient selectable from
TECHNICAL DATA - Relays digital input
(Up to 3), NO, max 3A, 250V resistive load.
Inputs
Application: cooling, alarms. Power Supply
Input range: 0...60mV.
- Logic 24Vdc 25%, max 5VA
Sampling time: 120msec.
24Vdc, 35mA.
Accuracy: 0.2%fs 1 scale points at 25C.

POWER MODULE

25A 40A 60A 75A 90A 120A

RATED VOLTAGE 480Vac
WORK VOLTAGE RANGE 24...530Vac
NON-REPETITIVE VOLTAGE 1200Vp
SWITCHING VOLTAGE FOR ZERO 20V
RATED FREQUENCY 50...60Hz
POWER FACTOR 0,5
RATED CURRENTAC1 25A 40A 60A 75A 90A 120A
REPETITIVE OVERCURRENT(t=1s) 40A 50A 100A 100A 150A 150A
NON-REPETITIVE OVERCURRENT(t=20ms) 400A 600A 1150A 1500A 1500A 1500A
I2t FOR BLOWOUT (t=1...10ms) 645A2s 1010A2s 6600A2s 8000A2s 11200A2s 11200A2s
CRITICAL dv/dt WITH OUTPUT DEACTIVATED 1000V/ms
RATED ISOLATION VOLTAGE IN/OUT 4000V
WORK 0...80C according to
TEMPERATURE dissipation curves

Height 225mm
Width 42mm 42mm 82mm 127mm 127mm 127mm
Depth 160mm 195mm 195mm 195mm 195mm 195mm
Weight 650gr 850gr 1300gr 1500gr 1500gr 1600gr
Protection class IP20
Installation DIN guide or panel
Notes MOV protection
High-speed fuses FUS-025 FUS-040 FUS-080 FUS-080 FUS-100 FUS-125N
DESCRIPTION OF FACEPLATE

GEFLEX 25A - 40A GEFLEX60A - 75A - 90A - 120A

POWER

High voltage lamp Connection button to DIN EN50022 guide

Load output connection Load common connection

Line input connection

Ground connection

CONTROL

Error LED (red)

Status LED (green) Main LED (yellow)

Fieldbus node selection

Connection to previous module

Connection to next module

Output terminal board

Probe and power supply terminal board

Fieldbus connection
DISSIPATION CURVES

Rated current curves based on room temperature.

Geflex 25 Geflex 40 Geflex 60

Geflex 75 Geflex 90 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.

TABLE FOR SELECTION OF WIRE TERMINALS FOR POWER AND SIGNAL TERMINAL BOARDS

Terminal contact Terminal hole Recommended

Level
area (LxD) diameter conductor section
25A 12 x 12mm 5mm 6mm2
POWER

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

Flexible wire conductor
SIGNAL

insulating collar
0.14 - 1.5mm2 / 28-16AWG 0.25 - 0.5mm2 / 24-20AWG
Cross-cut screwdriver, blade 0.4 x 2.5mm
TYPE OF OPERATION

Zero Crossing switching

Command from logic output in voltage

V
Control input

ON ON
OFF

V = Voltage on load

Power delivered = Installed power x TC / T

DIMENSIONS AND CUTOUT

25/40A 60A 90/120A

224

h (mm) 41 82 127
25A 160
40A ... 120A 195

25 53 53
40

212

212

212

Installation on electromagnetic plate

by means of quick coupling to
DIN EN50022 guide or with 5MA screws
(see TEMPLATE)

25 53 53
CONNECTION EXAMPLES

Connection of MASTER + SLAVE modules

LOAD 10

FUSE 10
LOAD 1

LOAD 2
FUSE 1

FUSE 2
M S1 S9

FIELDBUS

MASTER SLAVE1 SLAVE9

TO NEXT
GEFLEX MASTER

Three-phase connection
LOAD 1/3

LOAD 2/3

LOAD 3/3
FUSE 1

FUSE 2

FUSE 3

M E1 E2

FIELDBUS
MASTER

TO NEXT
GEFLEX MASTER
ELECTRICAL CONNECTIONS

Digital communication PROFIBUSDP Power

D-SUB connector 9-pin Male Three-phase line with neutral
Shielded cable 1 pair 22 AWG
consistent PROFIBUS

From PROFIBUS
network
LOAD FUSE

We advise you to connect a 220 1/4W resistance between the

RxD/TxD-P and RxD/TxD-N signals, a 390 1/4W resistance
between the RxD/TxD-P and Vp signals, and a 390 1/4W resi- Output Common
stance between the RxD/TxD-N and DGND signals at both ends
of the Profibus network. Input

Digital communication CANopen

Three-phase line without neutral
D-SUB Connector 9 pin Female
Shielded cable 2 pairs 22/24 AWG
consistent CANopen

From CANbus network LOAD

FUSE

We advise you to connect a 124 1/4W resistance between the Output Common
CAN_L and CAN_H signals at both ends of the CANbus network.
Input
Digital communication MODBUS
D-SUB Connector Shielded cable 1 pair 22 AWG The Input and Common connection to the network depend on the appli-
9-pin Male consistent MODBUS cation.
A wire with 0.5mm / 20AWG section is sufficient for the Common connec-
TX / RX+
From previous module tion.
on Modbus network
TX / RX-

Control
SCH

TC Pt100 LININP LININP

GND 3 wires Idc (20mA) Vdc (1V)
+ +
To next module on
TX / RX+

TX / RX-

Modbus network - T - -
+

L+ Digital input
L+
M Power supply (18...32Vdc)
PE
TX / RX+
TX /
TX / RX- From Modbus network
GND J3

We advise you to connect pins 6 to 7 and pins 8 to 9 on the con- J1 OUT 1 internal command
nector of the last Geflex on the Modbus network to insert the line 1 7 for solid state relay (HEAT)
termination.
1 8

We advise you to also connect the GND signal among Modbus J2

devices having a line distance > 100 m.

Digital communication DeviceNet

C3
NA3 OUT4 (AL2)

Shielded cable 2 pairs 22/24 AWG C2

Connector 5 pin OUT3 (AL1)
DeviceNet conformity NA2
V+
5

C1 (+)
OUT2 (COOL)
CAN_H
4

SHIELD NA1 (-)

3

CAN_L
2

V-
From DeviceNet network Legend (Logic output PNP18
1

J1: Probe and power supply terminal board 32Vdc optional not isola-
We advise you to connect a 120 1/4W resistance between the J2: Relay output terminal board ted from
CAN_L and CAN_H signals at both ends of the DeviceNet net- J3: Connection among modules power supply)
work.
ORDER CODE

Master GFX-M1 480 RR P

RATED CURRENT DIAGNOSTIC

Base Master 25-40A 00 None
B40
without solid state power unit
Base Master 60-120A C0 Current Transformer
B120
without solid state power unit
Current Transformer
CV
Solid state relay 25A 25 + Voltmeter Transformer
Solid state relay 40A 40
DIGITAL INPUT
Solid state relay 60A 60
P PNP Digital Input
Solid state relay 75A 75
Solid state relay 90A 90 AUXILIARY OUTPUTS
Solid state relay 120A 120 RR 2 Relays

COOLING OUTPUT
RATED VOLTAGE
480Vac 480 0 None
D Logic
DIGITAL COMMUNICATIONS R Relay
MODBUS RTU M
C Continuous output
PROFIBUS DP P 0...10V (0/4...20mA)
CANopen C
DeviceNet D
Ethernet Modbus TCP E

Slave GFX-S1 480 0 P

RATED CURRENT DIAGNOSTIC

Base Slave 25-40A 00 None
B40
without solid state power unit
C0 Current Transformer
Base Slave 60-120A
B120
without solid state power unit
Current Transformer
CV
Solid state relay 25A 25 + Voltmeter Transformer
Solid state relay 40A 40
DIGITAL INPUT
Solid state relay 60A 60
P PNP Digital Input
Solid state relay 75A 75
Solid state relay 90A 90 AUXILIARY OUTPUTS
Solid state relay 120A 120 00 Absent (**)
RR 2 Relays
RATED VOLTAGE
480Vac 480

COOLING OUTPUT (**) Option not available for current levels 75A, 90A and 120A
None 0
Logic D
Relay R
Continuous output C
0...10V (0/4...20mA)

Expansion GFX-E1 480 0 0 00 0

RATED CURRENT DIAGNOSTIC

Base Expansion 25-40A 00 None

B40
without solid state power unit
C0 Current Transformer
Base Expansion 60-120A
B120 Current Transformer
without solid state power unit CV
+ Voltmeter Transformer
Solid state relay 25A 25
Solid state relay 40A 40
Solid state relay 60A 60 RATED VOLTAGE
Solid state relay 75A 75 480 480Vac
Solid state relay 90A 90
Solid state relay 120A 120

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

Conformity C/UL/US File no. C/UL/US File no. E198546

The instrument conforms to the European Directives 2004/108/CE and 2006/95/CE with reference to the generic standards :
EN61326-1 EN (product),EN 61010-1 (safety)
GEFRANspa via Sebina, 74 - 25050 Provaglio dIseo (BS)
Tel.03098881 - fax 0309839063 - Internet: http://www.gefran.com DTS_GFX_05-2014_ENG