gefran 800 - User Manual

RTD type (scale configurable within indicated
range, with or without decimal point)
PTC type (on request)
DIN 43760 (Pt100, JPT100)
990Ω, 25°C
Max line resistance for RTD 20Ω
Safety
detection of short-circuit or opening of probes, LBA
alarm, HB alarm
°C / °F selection configurable from faceplate
Linear scale ranges -1999 to 9999 with configurable decimal point position
800
CONTROLLER
SOFTWARE VERSION 3.2x
code 80225E / Ed. 06- 04-2013
USER’S MANUAL
Thermocouples
IEC 584-1
(J, K, R, S, T, B, E, N, Ni-Ni18Mo, L NiCr-CuNi)
Cold junction error 0,1° / °C
Controls PID, Self-tuning, on-off
pb / dt / di 0.0 ... 999.9% / 0.00 ... 99.99min / 0.00 ... 99.99min
Action Heat / Cool
Control outputs on / off, pwm
Cycle time 0.1 ... 200 sec
Main output type Relay, Logic, Continuous (optional)
Softstart 0.0 ... 500.0 min
Maximum power limit heat / cool 0.0 ... 100.0 %
Fault power setting -100.0 ... 100.0 %
Automatic blanking Optional exclusion, displays PV value
Configurable alarms
3 configurable alarms type: max, min, symmetrical,
absolute or relative, LBA, HB
Alarm masking
- exclusion during warm up
- latching reset from faceplate or external contact
Type of relay contact NO (NC), 5A, 250V, cosj = 1
48
63
48
129
10
45
45
70
70
For correct and safe
installation, follow the
instructions and observe
the warnings contained in
this manual.
Faceplate protection IP65
Working / Storage temperature range 0...50°C / -20...70°C
Relative humidity 20 ... 85% non-condensing
Installation Panel, plug-in from front
Weight 210g for the complete version
Main input
TC, RTD (Pt100 - JPT100), PTC,
50mV, Ri ≥ 1MΩ, 10V, Ri ≥ 10KΩ, 20mA, Ri = 50W
CT scale range configurable from 0, ... , 100.0A
Transmitter power supply (optional)
filtered 10 / 24Vdc, max 30mA
short-circuit protection, isolation 1500V
Analogue retransmission signal (optional) 10V / 20mA, isolation 1500V
Logic inputs (optional)
24V NPN, 4.5mA; 24V PNP, 3.6mA isolation
1500V
Serial interface (optional) CL; RS422/485; RS232; isolation 1500V
Baud rate 1200 ... 19200
Protocol GEFRAN / MODBUS
Logic output for static relays 11Vdc, Rout = 220Ω (6V/20mA)
Remote setpoint or ammeter input
(options)
0 ... 10V, 2 ... 10V, Ri ≥ 1MΩ
0 ... 20mA, 4 ... 20mA, Ri = 5Ω
Potentiometer > 500Ω,
CT 50mAac, 50/60Hz, Ri = 1.5Ω,
isolation 1500V
Power supply (switching type)
(std) 100 ... 240Vac/dc ±10%; 50/60Hz, 12VA max
(opt.) 20...27Vac/dc ±10%; 50/60Hz, 12VA max
Display 2 x 4 digits, green, height 10 and 7mm
Keys 4 mechanical keys (Man/Auto, INC, DEC, F)
Accuracy 0.2% full scale at 25°C room temperature
1 • INSTALLATION
• Dimensions and cut-out; panel mounting
Panel mounting:
To fix the unit, insert the brackets provided into the seats on either side of the
case. To mount two or more units side by side, respect the cut-out dimensions
shown in the drawing.
CE MARKING: The instrument conforms to the European Directives 2004/108/CE and
2006/95/CE with reference to the generic standards: EN 61000-6-2 (immunity in industrial
environment) EN 61000-6-3 (emission in residential environment) EN 61010-1 (safety).
MAINTENANCE: Repairs must be done only by trained and specialized personnel. Cut
power to the device before accessing internal parts.
Do not clean the case with hydrocarbon-based solvents (Petrol, Trichlorethylene, etc.).
Use of these solvents can reduce the mechanical reliability of the device. Use a cloth
dampened in ethyl alcohol or water to clean the external plastic case.
SERVICE: GEFRAN has a service department. The warranty excludes defects caused
by any use not conforming to these instructions.
2 • TECHNICAL SPECIFICATIONS
FUNCTION CABLE TYPE LENGTH
Power supply cable 1 mm
2
1 m
Relay output cable 1 mm
2
3,5 m
Digital communication cable 0,35 mm
2
3,5 m
C.T. connection cable 1,5 mm
2
3,5 m
TC input 0,8 mm
2
compensated 5 m
Pt100 input 1 mm
2
3 m
EMC conformity has been tested with the following connections
!
Environmental conditions of use for internal use only, altitude up to 2000m
1
80225E_MHW_800_04-2013_ENG

Summary

1. INSTALLATION

Panel Mounting

Details for mounting the controller in a panel.

2. TECHNICAL SPECIFICATIONS

4. CONNECTIONS

Serial Line and Communication

Input and Output Terminals

Wiring details for various analogue and digital inputs/outputs.

Power Supply and Auxiliary Inputs

5. RECOMMENDED WIRING LAYOUT

5. PROGRAMMING and CONFIGURATION

Menu Structure and Navigation

INFO, SEr, InP, and Out Menu Settings

Configuring information, serial, input, and output parameters.

CFG Menu for Control Parameters

Accessing and modifying core control parameters within the CFG menu.

CFG Menu Parameters

Protection, Tuning, and Limit Settings

PID Control Parameter Adjustment

Detailed settings for Proportional, Integral, and Derivative control actions.

Alarm Configuration and Fault Settings

Serial Communication Parameters

Input Configuration Parameters

Setpoint Type and Probe Configuration

Selecting setpoint types and configuring various sensor probe inputs.

Signal Type and Scale Range Setup

Output Configuration Parameters

Alarm Types and HB Alarm Function

Defining alarm conditions and configuring the HB alarm functionality.

Output Signal Allocation

Assigning Reference Signals to Outputs

Protection Code Settings

Hardware Configuration Menu

Main Hardware Setup (hrd.1)

Configuring probe types, digital inputs, and serial interface options.

Output and Timer Configuration (hrd.2, hrd.3)

Control Type and Digital Input Functions

Selecting control strategies and configuring digital input logic.

6. TIMER + 2 SET POINT, TIMER FUNCTION

Timer Operation and Set Point Control

How the timer function controls set points and operation modes.

7. MULTISET FUNCTION, SET GRADIENT

MultiSet and Set Gradient Configuration

Setting multiple set points and adjusting set point change speed.

8. ALARMS

Alarm Types and Behavior

Description of absolute, deviation, HB, and LBA alarm types.

HB and LBA Alarm Configuration

Detailed setup for Heat Break and Loop Break alarms.

9. SOFT-START

10 CONTROL ACTIONS

PID Control Action Influence

11. MANUAL TUNING

PID Parameter Tuning Process

Step-by-step guide for manually tuning PID parameters.

13 SELF-TUNING

Activating and Performing Self-Tuning

Guide to activating and executing the self-tuning process for PID parameters.

15 CONTROL OUTPUT

Heating;Cooling Control with Relative Gain

16. MAIN INPUT CORRECTION FUNCTION

Safety Warnings

General Device Safety Precautions

Essential warnings for safe installation, connection, and operation.

Electrical and Installation Safety

Specific safety guidelines for power supply, wiring, and installation.

Jumper Configuration

Board Identification and Jumper Functions

Specific Jumper Settings (S3-S13)

Analogue Output Configuration

Output W1 and W2 Signal Setup

Serial and SPR Input Configuration

SPR Input Type Configuration

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The Gefran 800 Controller is a versatile process variable controller designed for a wide range of industrial applications, offering precise control and extensive configuration options.

Function Description

The controller features a 2 x 4 digit green display (10mm and 7mm height) for clear visualization of process variables (PV) and setpoints (SV). It is equipped with four mechanical keys (Man/Auto, INC, DEC, F) for easy navigation and parameter adjustment. The device supports various input types including thermocouples (TC), Resistance Temperature Detectors (RTD) like Pt100 and JPT100, PTC thermistors, 50mV, 10V, and 20mA signals, ensuring compatibility with diverse sensors.

Control actions include PID, self-tuning, and on-off control, with configurable proportional band, integral time, and derivative time. It supports both heat and cool control, with options for relay, logic, or continuous outputs. The cycle time for outputs is adjustable from 0.1 to 200 seconds. Softstart functionality allows for a gradual power ramp-up, configurable from 0.0 to 500.0 minutes.

The controller incorporates robust safety features such as detection of short-circuit or open probes, Load Break Alarm (LBA), and Heater Break (HB) alarm. LBA detects interruptions in the control loop due to short-circuited probes, inverted probe connections, or broken loads, tripping if the variable does not increase/decrease at maximum power for a set time. HB alarm monitors load current via a current transformer input, tripping if the current falls below a setpoint during ON time or exceeds 12% of full scale during OFF time. These alarms are configurable from the faceplate, with options for max, min, symmetrical, absolute, or relative types, and can be masked during warm-up or reset via faceplate or external contact.

The device offers configurable linear scale ranges from -1999 to 9999 with adjustable decimal point positions. It includes three configurable alarms (AL1, AL2, AL3) with various types and hysteresis settings. An optional auxiliary input can be configured for remote setpoint, ammeter input, or analogue power reset, supporting 0-10V, 2-10V, 0-20mA, 4-20mA, potentiometer, or 50mAac CT signals. An optional analogue retransmission signal (10V/20mA) is also available.

Two logic inputs (24V NPN/PNP) are available, isolated to 1500V. Serial communication is supported via RS422/485 or RS232, with configurable baud rates (1200-19200) and protocols (GEFRAN/MODBUS), isolated to 1500V.

The controller also features a "Timer + 2 Set Point" function, enabling time-based control with two setpoints, activated by external contacts or alarms. The "Multiset Function, Set Gradient" allows for up to four setpoints selectable via digital inputs, with a configurable gradient for smooth setpoint transitions.

Important Technical Specifications

• Display: 2 x 4 digits, green, 10mm and 7mm height.
• Accuracy: 0.2% full scale at 25°C room temperature.
• Main Input Types: TC (J, K, R, S, T, B, E, N, Ni-Ni18Mo, L NiCr-CuNi), RTD (Pt100, JPT100), PTC (990Ω, 25°C), 50mV, 10V, 20mA.
• Cold Junction Error: 0.1°/°C.
• Max Line Resistance for RTD: 20Ω.
• Control Actions: PID, Self-tuning, On-off.
• Control Outputs: Relay (5A, 250V), Logic (11Vdc, Rout=2200Ω), Continuous (optional).
• Cycle Time: 0.1 to 200 seconds.
• Softstart Time: 0.0 to 500.0 minutes.
• Alarms: 3 configurable alarms (max, min, symmetrical, absolute, relative, LBA, HB).
• Auxiliary Input (optional): 0-10V, 2-10V, 0-20mA, 4-20mA, Potentiometer (>5000Ω), CT 50mAac (50/60Hz, Ri=1.5Ω), isolated 1500V.
• Transmitter Power Supply (optional): 10/24Vdc, max 30mA, short-circuit protection, isolated 1500V.
• Analogue Retransmission Signal (optional): 10V / 20mA, isolated 1500V.
• Logic Inputs (optional): 24V NPN (4.5mA), 24V PNP (3.6mA), isolated 1500V.
• Serial Interface (optional): CL, RS422/485, RS232, isolated 1500V.
• Baud Rate: 1200 to 19200.
• Protocol: GEFRAN / MODBUS.
• Power Supply: 100-240Vac/dc ±10% (50/60Hz, 12VA max) or 20-27Vac/dc ±10% (50/60Hz, 12VA max).
• Faceplate Protection: IP65.
• Working Temperature Range: 0 to 50°C.
• Storage Temperature Range: -20 to 70°C.
• Relative Humidity: 20 to 85% non-condensing.
• Installation: Panel, plug-in from front.
• Weight: 210g for the complete version.
• EMC Conformity: EN 61000-6-2 (immunity), EN 61000-6-3 (emission).
• Safety: EN 61010-1.

Usage Features

• User-Friendly Interface: The 4-key interface and clear display facilitate easy parameter setup and monitoring.
• Self-Tuning and Auto-Tuning: The controller offers both self-tuning for optimal PID parameter calculation during startup and auto-tuning for continuous optimization during operation, adapting to process changes.
• Main Input Correction Function: Allows for custom correction of main input readings by setting four values (A1, B1, A2, B2), useful for non-linear sensors or specific calibration needs.
• Software ON/OFF Switching: The unit can be switched ON or OFF via a key combination, disabling all outputs and functions except communication, useful for maintenance or system shutdowns.
• Custom Menu: A "dAtA" menu allows users to set custom parameters, enhancing flexibility for specific applications.
• Password Protection: Access to configuration menus can be protected by a password, preventing unauthorized changes.
• Input Linearization: Custom linearization can be applied to main or auxiliary inputs for enhanced accuracy with non-linear sensors.

Maintenance Features

• Specialized Repairs: Repairs must only be performed by trained and specialized personnel.
• Power Disconnection: Always cut power to the device before accessing internal parts to ensure safety.
• Cleaning Instructions: The external plastic case should be cleaned with a cloth dampened in ethyl alcohol or water. Avoid hydrocarbon-based solvents (Petrol, Trichlorethylene, etc.), as they can reduce mechanical reliability.
• Service Department: Gefran provides a service department for support, and the warranty excludes defects caused by non-conforming use.
• EMC Conformity: The device is designed and tested for EMC conformity, ensuring reliable operation in industrial environments.
• Installation Guidelines: Detailed instructions are provided for correct and safe installation, including panel mounting dimensions, wiring layouts, and environmental considerations to prevent damage and ensure optimal performance. This includes separating power supply lines from input/output lines, using twisted and screened cables for analog inputs, and installing RC groups for inductive loads.

gefran 800 Specifications