GEM1&2CVR-m.
GEM1&2CVR-m.QXD 4/21/05 1:14 PM Page 2 INTRODUCTION The Gemini 1000 and 2000 are both units in a multi-purpose series of industrial control units that are field-programmable to solve multiple applications. This series, known as the Astro-Line family of products, is built around the concept that the end user has the capability to program different personalities and functions into the unit in order to adapt to different indication and control requirements.
TABLE OF CONTENTS I. GENERAL DESCRIPTION Safety Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming The Gemini 1000/2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming The Personality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming The Presets, Scale Factor, & Output Time Delays. . . . . . . . . . . . . . . . . . . . . . . . Factory Settings . . . . . . .
GENERAL DESCRIPTION Preset and reset behavior of the output(s) and display are completely programmable. The preset(s) can have a value ranging from -999999 to +999999. Decimal placement will be the same as the decimal placement on the input value. Various reset modes can be selected: manual reset to zero or preset; automatic reset to zero or preset; or automatic reset after time delay. The manual reset will always override automatic reset, if it has been enabled.
PROGRAMMING THE PRESETS, SCALE FACTOR, & OUTPUT TIME DELAYS Data for the presets, scale factor, and time delays are entered differently. Each digit key controls the digit on the display directly above it. Changing the digits can be done by repeatedly pressing the key beneath the digit position you wish to change or by merely holding it down. As you hold it down or press it, the value of that digit will change cyclically, counting up to 9, then to 0, and then up again.
PROGRAMMING THE PRESETS, SCALE FACTOR, & OUTPUT TIME DELAYS (Cont’d) Note: A time delay value of zero cannot be programmed into the Gemini. If a value of 0 is entered into the display and the “E” key is pressed, the unit will continue to use the previous time delay value. The preset level is changed in the same way as the scale factor. Pressing the “1” key will display the present value of preset 1. As with the other functions, you must press “E” to record the changes.
FACTORY SETTINGS Keys Struck 4,1 4,3 4,4 4,5 4,6 5,1 5,2 5,3 Display 41 1 43 1 44 1 45 1 46 1 51 1 52 3 0000.10 *5,4 *5,5 54 3 0000.10 6,1 6,6 3 1 *2 61 4 66 4 01.0000 000500 001000 Description Personality selected as Counter Count with Inhibit Count on one edge of input (no doubling) Scale Multiplier of 1.0 Leading zero blanking and no decimal point Manual reset-to-zero, as long as button remains PUSHED Output 1 terminates at Reset, Normal Output Phase 0.10 second Output 1 time delay.
OPERATOR ACCESSIBLE FUNCTIONS WITH PROGRAMMING DISABLED used in conjunction with any front panel disable mode. The combination of manual and remote inputs provides a high level of security without sacrificing flexibility. (For details on keyboard entry, see preceding section) DIAGNOSTICS, SELF TEST, & “WATCHDOG” TIMER One of the important features of the Gemini is the ability to disable programming.
An automatic exit will take place after six seconds or immediately if the Program Disable terminal is connected to common. Normal length of display time for each of the patterns is approximately 0.5 seconds. Rapidly pressing the “+/-” key during self test can speed up the process. INPUT CIRCUITRY & SET-UP There are two independent input channels on the Gemini.
PROGRAMMING INSTRUCTIONS FOR THE COUNTER VERSION OF THE GEMINI [43 3] TWO (2) INPUT ANTI-COINCIDENCE ADD/SUBTRACT - This mode effectively separates count pulses which may simultaneously appear at the two inputs. The Gemini unit then processes the count pulses into a string of time-separated pulses, so the internal counter will not lose any counts. Input A serves as the add input, and Input B serves as the subtract input.
CODE 44 - NUMBER OF COUNT EDGES 1] 2] 3] 4] 5] 6] 0 0.0 0.0 0 0.0 0 0 0.0 0 0 0 0.0 0 0 0 0 LEADING ZERO BLANKING [46 -1] [46 -2] [46 -3] [46 -4] [46 -5] [46 -6] 000000 0 0 0 0 0.0 0 0 0 0.0 0 0 0 0.0 0 0 0 0.0 0 0 0 0.0 0 0 0 0 LEADING ZERO BLANKING INHIBITED [46 [46 [46 [46 [46 [46 The Gemini can be programmed for either single edge or two edge (doubling) counting.
CODE 51 - RESET MODES (Cont’d) preset is reached. The reset condition of the output is output on. (Note: The state of the relay, if used, is also reversed.) A “-” sign in front of the mode identifier will provide for reverse phase operation. The absence of a “-” sign will give normal phase operation. In all modes except boundary, when the unit is powered up, the relays or outputs will be turned off. This is done to help prevent a hazardous situation from occurring.
[52 -1] [52 -2] [52 -3] [52 -4] [52 -5] [52 -6] [54 1] TERMINATE AT OUTPUT 1 START - Output 2 will terminate when Output 1 starts. [54 2] TERMINATE AT OUTPUT 1 END - Output 2 will terminate when Output 1 terminates. [54 3] TERMINATE AT MANUAL RESET - In this mode, output 2, once activated, does not deactivate until the moment a reset occurs. The reset can be from the front panel button or from the remote reset terminal, at the rear of the unit. The output is set for normal phase operation.
CODE 55 - OUTPUT 2 TIME DELAY (GEMINI 2000 Only) [66 2] PRESET PROGRAMMING AND RESET ENABLED - In this mode, manual reset and the programming of the Preset Values are enabled. [66 3] SCALE FACTOR PROGRAMMING AND RESET ENABLED - In this mode, manual reset and the programming of the Preset values are enabled. [66 4] SCALE FACTOR, PRESET PROGRAMMING AND RESET ENABLED - In this mode, manual reset and the programming of the Scale Factor and Preset Values are enabled.
It is important to note that the precision of an application cannot be improved by using a scale factor greater than one. To accomplish greater precision, more pulse information must be generated per measuring unit. For example, if 5 pulses are being received per foot of material, the precision of 10th of feet cannot be attained by simply programming a 2.000 scale factor, even though the display is reading in tenths. In this case, the display will increment by two for each count input.
DUAL PRESET COUNTING & PROGRAMMING APPLICATION EXAMPLE A typical industrial application for Gemini 2000 will require both a slow down output and a final stop output. The Gemini can easily be programmed to solve this requirement. For instance, let’s look at a textile web process that requires a dual output as the web progresses to the proper length. A typical length of material for this application is 10,000 feet for total length, and a slow down output 500 feet prior to the end of the 10,000 foot length.
HARDWARE SET-UP STEP 6 - Enter function code 51 (Reset Modes), and enter a mode identifier of 2 for Manual reset to Preset 2. This mode was chosen to allow set-up time for a new roll or take-up spool. STEP 7 - Enter function code 52 (Output 1 Termination Modes), and enter a mode identifier of 3 (Terminate at Start of Manual Reset). Output 1 is the slow down output which once activated should remain so until the unit is reset for start up.
PROGRAMMING INSTRUCTIONS FOR THE RATE INDICATOR VERSION OF THE GEMINI [45 1] SCALE MULTIPLIER VALUE OF 1 - This value multiplies the internal rate by 1. [45 2] SCALE MULTIPLIER VALUE OF 0.1 - This value multiplies the internal rate by 0.1. (Effectively divides by 10.) [45 3] SCALE MULTIPLIER VALUE OF 0.01 - This value multiplies the internal rate by 0.01. (Effectively divides by 100.) [45 4] SCALE MULTIPLIER VALUE OF 0.001 - This value multiplies the internal rate by 0.001. (Effectively divides by 1000.
Scale Factor), the output is not activated when the rate value is more positive than the preset value. When the rate value is more negative than or equal to the preset, the output is activated. If the rate value becomes more positive than the preset, the output again deactivates. The output is set for normal phase. the case with all standard rate indicators.
CODE 54 - OUTPUT 2 TERMINATION MODES (Gemini 2000 Only) The Gemini 2000 has two standard Output 2 Termination Modes when operating as a rate indicator. They are terminate After Time Delay and Boundary. A Reverse Phase Option is available on the Gemini 2000. This refers to complementing the logic state of the output. For normal phase operation, the reset condition of the output is output off. For reverse phase operation, the reset condition of the output is output on.
CODE 63 - SAMPLE TIME [66 -1] [66 -2] [66 -3] [66 -4] The Gemini offers six different lengths of sample times. They are 1 second; 2 seconds; 5 seconds; 10 seconds; 20 seconds; and 50 seconds. Sample Time is defined as the time period allowed for input pulses to accumulate. At the conclusion of this time period, the number of pulses which occur during the sample time, is multiplied by the programmed scale factor value and then displayed.
DUAL PRESET RATE PROGRAMMING APPLICATION EXAMPLE A typical industrial Dual preset rate indicator application would be the speed control of a web press operation in a newspaper plant. The Gemini 2000 as pictured, is programmed to read out in feet/min. every two seconds. The input is from the rotary pulse generator that is attached on the drive roll. In this case, the RPG is delivering 120 pulses/rev. and the circumference of the roll is 6.35 ft.
HARDWARE SET-UP STEP 3 - Enter code 45 (Scale Multiplier Values), and enter a mode identifier of 1 for a scale multiplier of 1. STEP 4 - Enter code 46 (Decimal Point and Leading Zero Blanking) and enter 1 for no decimal points and lead zero blanking. STEP 5 - Enter code 52 (Output 1 Termination Modes) and enter 5 for time delay operation. STEP 6 - Enter code 53 (Output 1 Time Delay) and enter a time delay value of 0000.50.
GEMINI 2000 20 mA CURRENT LOOP COMMUNICATIONS The Gemini 2000 20 mA Current Loop Communications Option allows a “two-way” serial communications link to be established in order to monitor or change the count value, Presets and Scale Factor from a remote location. Some typical devices that can be connected with the Gemini 2000 are: a printer, terminal, programmable controller, or host computer.
As shown, all commands must be terminated with a “Command Terminator” (* or 2AH). The Gemini 2000 will not process the command until the terminator is sent. If illegal commands or characters are sent to the Gemini 2000, they still would need to be terminated by an (*). If they are not terminated, the next command will not be accepted.
RECEIVING DATA FROM THE GEMINI 2000 When the Print ID switch is in the down position, the unit will not transmit the characters before the data value (address, Value ID, spaces) or the 400 msec printer delay. The same above value when transmitted with the “PR.ID” switch in the down position, is transmitted as: -1234.56 < CR> < LF> Note: When using the Gemini with a printer, with the “Print ID” switch in the down position, some printers may not work, since the printer delay is not transmitted.
CURRENT LOOP INSTALLATION WIRING CONNECTIONS When wiring the 20 mA current loop, remove the 7-position terminal block (TBD), located on the right side of the top board. Refer to the numbers listed with the terminal descriptions below or on the top label, and install each wire in its proper location on the terminal block. When all connections are made, replace the terminal block into its proper location. It is recommended that shielded (screened) cable be used for serial communications.
CURRENT LOOP INSTALLATION (Cont’d) When the switch is in the down position, the Gemini 2000 will transmit only the data value, without the unit address and data ID. The 400 msec delay, described above, will not be inserted. This switch position usage is intended for applications where the Gemini is communicating with a computer. In these circumstances printing the address and value ID and inserting a 400 msec print delay is usually unnecessary and needlessly slows down communication throughput.
COMMUNICATIONS APPLICATION PROCESS MONITORING SYSTEM Five Gemini 2000s with 20 mA Current Loop Option, are used to monitor and control parts packaging machines in a plant. The units are located at each of the machines in the production area of the building. The communications lines are run to an Industrial computer located in the production offices. The drawing below shows the Current Loop set-up. Each Gemini 2000 is given an address and the Serial DIP switches are set accordingly.
TROUBLESHOOTING GEMINI SERIAL COMMUNICATIONS SERIAL LOOP-BACK SELF-TEST If problems are encountered when trying to get the Gemini(s) and host device or printer to communicate, the following checklist can be used to help find the solution. The Gemini 2000 has a Serial Loop-back Self-test feature. This test enables the user to verify the operation of the Gemini when problems are encountered trying to get the Gemini and “Host device” communicating.
APPENDIX “A” - INSTALLATION & INPUT CONFIGURATION SWITCH SET-UP Installation Environment Before installing the Gemini into the panel, the user should first become familiar with the unit. It may also be desirable to program the unit for the application at hand (Refer to the “Programming and Applications” sections). Once the unit is programmed, the settings will be saved in memory. The Program Disable “PGM. DIS.” terminal should be connected to “COMM.
GEMINI 1000 BLOCK DIAGRAM –30–
GEMINI 2000 BLOCK DIAGRAM –31–
SELECT AC POWER (115/230 VAC) Shield Termination The AC power to the unit must be selected for either 115 VAC or 230 VAC. The selector switch is located through an access slot on the side of the case (See the Installation Figure on the previous page, or the label on the case). The unit is shipped from the factory with the switch in the 230 VAC position. Caution: Damage to the unit may occur if the AC selector switch is set incorrectly.
Additional EMC Installation Guidelines several times or use multiple cores on each cable for additional protection. Install line filters on the power input cable to the unit to suppress power line interference. Install them near the power entry point of the enclosure.
PRIMARY A.C. POWER WIRING SERIAL COMMUNICATIONS For best results, the A.C. primary power should be relatively “clean” and within the specified +/-10% variation limits. Drawing power from heavily loaded circuits or from circuits that also power loads that cycle on and off, should be avoided. The AC power is connected to the bottom left terminals TBA 1 & 2, marked as AC Power, 50/60 Hz. The voltage selector switch, located on the side of the unit, is used to select the proper voltage.
INSTALLATION & REMOVAL OF THE RELAY BOARD NOTES: 1. SENSOR VOLTAGE AND CURRENT The +12 V sensor supply voltage on the “DC OUT” terminal is nominal with +/-25% variation due to line and internal load variations. All RLC sensors will accommodate this variation. 2. HI/LO FRQ SELECTION The HI/LO FRQ selection switch must be set on “LO FRQ” when switch contacts are used to generate count input signals.
GEMINI 1000 CONNECTIONS & CONFIGURATION SWITCH SET-UPS FOR VARIOUS SENSOR OUTPUTS (SEE NOTE 5) –36–
GEMINI 2000 CONNECTIONS & CONFIGURATION SWITCH SET-UPS FOR VARIOUS SENSOR OUTPUTS (SEE NOTE 5) –37–
GEMINI 1000 SENSOR INPUT CONNECTIONS & INPUT CONFIGURATION SWITCH SET-UP CHAN. B CHANNEL A The accompanying diagram shows the details of the count Input A and magnetic pickup circuit. The schematic circuit for Input B is almost identical to that of Input A, with the exception that Input B does not have the Magnetic Pickup circuitry paralleled with it. The four switches used to set up Input A and the Magnetic Pickup are designated S1, S2, S3, and S4. To set up Input B; use switches S5, S6, and S7.
GEMINI 2000 SENSOR INPUT CONNECTIONS & INPUT CONFIGURATION SWITCH SET-UP CHAN. B CHANNEL A The accompanying diagram shows the details of the count Input A and magnetic pickup circuit. The schematic circuit for Input B is almost identical to that of Input A, with the exception that Input B does not have the Magnetic Pickup circuitry paralleled with it. The four switches used to set up Input A and the Magnetic Pickup are designated S1, S2, S3, and S4. To set up Input B; use switches S5, S6, and S7.
APPENDIX “B” - SPECIFICATIONS & DIMENSIONS 1. DISPLAY: 6-digit, 0.56" (14.2 mm) High LED display. 2. POWER REQUIREMENTS: AC Power: Switch selectable 115/230 VAC (±10%), 50/60 Hz, 20 VA DC Power: 11 to 14 VDC @ 0.7 amp maximum 3. SENSOR POWER: +12 VDC (±25%) @ 100 mA. 4. MEMORY: Non-volatile E2PROM memory retains all programming information and count value when power is removed or interrupted. 5.
9. SERIAL COMMUNICATIONS (Optional): (Cont’d) Serial Hardware Specifications SO - Output Transistor Rating: VMAX = 30 VDC, VSAT = 1 VMAX at 20 mA. (Can address 16 units in a loop) SI - Input Diode Rating: VF = 1.25 VTYP; 1.5 VMAX Note: The compliance voltage rating of the source must be greater than the sum of the voltage drops around the loop. 10. OUTPUT(S): Solid-State - Current sinking NPN open collector transistor(s). ISNK = 100 mA maximum. VOH = 30 VDC maximum (Internal Zener diode protected).
APPENDIX “C” - TROUBLESHOOTING GUIDE The majority of difficulties arising with the Gemini 2000 are related to incorrect power hook-up and programming set-up. Always check all connections, function codes, Scale Factor, and presets as a first step in troubleshooting. Before applying power, double check all wiring. Improper AC voltage or AC connections may result in permanent damage to the unit.
APPENDIX “C” - TROUBLESHOOTING GUIDE (Cont’d) PROBLEM POSSIBLE CAUSE REMEDIES UNIT WILL NOT ACCEPT THE DESIRED PRESET VALUE 1. When scale factors greater than 1 are used, the preset value must be evenly divisible by the scale factor value. 1. Unit automatically adjusts preset value to be evenly divisible by the scale factor value. UNIT COUNTS INCORRECTLY 1. Input type incorrectly selected. 2. Inputs incorrectly connected or loose connections. 3. Electrical interference. 4. Wrong counting mode. 5.
APPENDIX “C” - TROUBLESHOOTING GUIDE (Cont’d) PROBLEM POSSIBLE CAUSE REMEDIES CANNOT PROGRAM CODE 52 - 1 , 2 1. 54 -6 is programmed. 2. Unit is in tachometer mode. 1. Change 54 then program 52. CANNOT PROGRAM CODE 52 - 6 1. 54 - 1, 2 is programmed. 2. Unit is in tachometer mode. 1. Change 54 then program 52. CANNOT PROGRAM CODE 54 - 1, 2 1. 52 -6 is programmed. 2. Unit is in tachometer mode. 1. Change 52 then program 54. CANNOT PROGRAM CODE 54 - 6 1. 52 -1, 2 is programmed. 2.
APPENDIX “D” - GEMINI FUNCTION COMMAND CODE SUMMARY CODE 41 43 MODE 1 2 DESCRIPTION UNIT PERSONALITY Counter Rate COMMENTS INPUTS A & B RESPONSE MODES (counter only) Count with Inhibit Count with Up/Down Control Input Anti-Coincidence Add/Subtract Input Anti-Coincidence Add Quadrature Quadrature x4 44 NUMBER OF COUNT EDGES 1 1 2 2 45 SCALE MULTIPLIER 1 1 2 0.1 3 0.01 4 0.
APPENDIX “D” - GEMINI FUNCTION COMMAND CODE SUMMARY (Con’t) CODE 51 MODE +/-1 DESCRIPTION RESET MODES (+) Maintained (-) Momentary COMMENTS Unit will remain reset as long as reset is activated. Unit will reset instantly and will start counting again even if reset is still activated.* Automatically selected when Rate or Boundary [54 6],is programmed, all others are locked out.
APPENDIX “D” - GEMINI FUNCTION COMMAND CODE SUMMARY (Con’t) CODE 54 MODE DESCRIPTION COMMENTS OUTPUT 2 TERMINATION (Con’t) +/-5 Terminate after Output 2 Time Delay +/-6 Boundary Automatically selects [51 1]. 55 NA OUTPUT 2 TIME DELAY (Gemini 2000 Only) Range 0.01 to 599.99 sec.
APPENDIX “E” - SCALING FOR RATE INDICATION APPLICATION EXAMPLE [A] The Gemini offers a simplified method of scaling a rate indication display. This unit offers the capability to monitor the entire range of any linear rate process. Numerous programming capabilities that are available with the Gemini, make this unit the most versatile rate indicator on the market today. The Gemini is designed to internally count input pulses for a programmable sample time period.
In this application, the 5.9999 scale factor has been exceeded. To complete the requirements, the calculated scale factor 8.68 is divided by 2, and the resultant 4.34 is loaded into the scale factor. Then the Function Code 44 (number of count edges) is programmed [44 2], which doubles the input pulse rate, and causes the Gemini to register the correct display at the 4.34 scale factor level. 4.
-50-
–51–
-52-
-53-
APPENDIX “G” - ORDERING INFORMATION MODEL NO. DESCRIPTION GEM1 Gemini 1000 GEM2 Gemini 2000 OPTIONS PART NUMBERS W/Relay Board W/20 mA Current Loop 115/230 VAC Yes No GEM10060 Yes No GEM20060 Yes Yes GEM20160 ¾ Gemini 1000 Relay Board RLYBD000 ¾ Gemini 2000 Relay Board RLYBD002 For Information on Pricing, Enclosures, Base Mount Kits, & Panel Adapter Kits, refer to the Red Lion Controls Catalog or contact your local RLC distributor.
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GEM1&2CVR-m.QXD 4/21/05 1:14 PM Page 3 LIMITED WARRANTY The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to one year from the date of shipment, provided the products have been stored, handled, installed, and used under proper conditions. The Company’s liability under this limited warranty shall extend only to the repair or replacement of a defective product, at The Company’s option.
GEM1&2CVR-m.QXD 4/21/05 1:14 PM Page 4 GEM2 / IM - M 4/05 DRAWING NO.
