Gemini 4100, 4200 Instruction Manual

THE ASTRO LINE SERIES

GEMINI 4000 INSTRUCTION MANUAL

Phone: [phone] - Fax: [phone] - Web: www.clrwtr.com - Email: [e-mail]

INTRODUCTION

The Gemini 4100 and 4200 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.

The Gemini, which you have purchased, has the same high quality
workmanship and advanced technological capabilities that have made Red Lion
Controls the leader in today's industrial market.

Red Lion Controls has a complete line of industrial indication and control
equipment, and we look forward to being of service to you now and in the future.

CAUTION: Risk of Danger.

Read complete instructions prior to

installation and operation of the unit.

CAUTION: Risk of electric shock.

Phone: [phone] - Fax: [phone] - Web: www.clrwtr.com - Email: [e-mail]

T ABLE OF CONTENTS

I. GENERAL DESCRIPTION 2

A) Safety Summary

2

B) Programming The Gemini

3

C) Programming The Personality

3

D) Programming The Presets, Scale Factors, Timed Outputs & Counter Load Values

3-5

E) Initial Factory Configuration Counter/Rate & Dual Counter Factory Settings

6

F) Operator Accessible Functions With Programming Disabled

7

G) Diagnostics, Self-Test, & “Watchdog” Timer

7-8

H) Input Circuitry & Set-up

8

I) Overflow Indication

8

II. PROGRAMMING INSTRUCTIONS FOR THE COUNTER/RATE VERSION OF THE GEMINI

9

A) Codes 41, 42, 43, 44, 45, & 46, 51, 52, 53, 54, 55, & 56

9-14

B) Codes 61, 62, 63, 64, 65, 66, Preset Values, Scale FactorsA&B,Counter Load Value

15-17

C) Dual Preset Counter & Rate Application

18-19

III. PROGRAMMING INSTRUCTIONS FOR THE DUAL COUNTER VERSION OF THE GEMINI

20

A) Codes 41, 42, 43, 44, 45, & 46

20-22

B) Codes 51, 52, 53, 54, 55, & 56

22-25

C) Codes 61, 64, 65, 66, Preset Values, Scale FactorsA&B,Counter Load Values

25-27

E) Dual Counter Batching Application

28-29

IV. 20 MA CURRENT LOOP COMMUNICATIONS

30

A) Communication Format

30

B) Sending Commands & Data To The Gemini

30-32

C) Receiving Data From The Gemini

32

D) Print Options

33

E) Current Loop Installation

34

F) Communications Application

35

G) Troubleshooting Gemini Serial Communications & Serial Loop-Back Self-Test

36

V. APPENDIX “A” - INSTALLATION & INPUT CONFIGURATION SWITCH SET-UP

37-45

VI. APPENDIX “B” - SPECIFICATIONS & DIMENSIONS

46-47

VII. APPENDIX “C” - TROUBLESHOOTING GUIDE

48-49

VIII. APPENDIX “D” - COUNTER/RATE & DUAL COUNTER MODE FUNCTION COMMAND CODE SUMMARY 50-57
IX. APPENDIX “E” - SCALING FOR COUNTING

58-59

X. APPENDIX “F” - SCALING FOR RATE

60-61

XI. APPENDIX “G” - GEMINI 4100 PROGRAMMING CHARTS

62-64

XII. APPENDIX “H” - GEMINI 4200 PROGRAMMING CHARTS

65-69

XIII. APPENDIX “I” - ORDERING INFORMATION

70

GENERAL DESCRIPTION

The Gemini 4000 series (4100 & 4200) instruments are two input
microprocessor based dual function counter/rate or dual counter instruments.
The 6-digit display features 0.56" high LEDs with negative sign, overflow and
displayed value indicators (A & B) located to the left of the display. When
programmedasa counter/rateinstrument,the Aindicator willbe on whenthe rate
is displayed and the B indicator will be on when the count is being displayed.
Pushing the “+/-” button toggles the display between the counter and rate or the
two counters depending on the personality selected.

TheGemini 4000 seriesconsists of two basicunits, a single presetversion, the
Gemini 4100, and a two preset version, the Gemini 4200. Each basic unit is also
availablein 115/230VAC versions,with orwithout Serialcommunicationsand a
relay board. The 20 mA current loop option (serial communications) makes
possible remote or computerized monitoringor control of the Count, Presets and
Scale Factors.

Flexibility and usefulness are insured through user programmability. With
simplefront panelkeystrokes and rearpanel switch settings, any one of anumber
of configurations can be selected. Once the selection is made, all or part of the
keyboard can be disabled to protect the settings and guarantee that no unwanted
changes can occur during the measurements.

Eachtime the power is turned off,the unit automaticallysaves the settings and
data in its special no power memory. When power is restored, the Gemini sets
itself back to the operational modes and restores the data it h ad at power down.
The “no power” E

2

PROM’s life expectancy is at least 100,000 cycles of power

being applied to and removed from the unit.

Whenever the power comes on, the Gemini performs a series of internal
diagnosticsto verify theintegrity of the storeddata. There isalso a self-test mode
and a “watchdog” timer to help prevent processor lockup.

TheGemini 4000 series counters can accept bi-directional, uni-directional, or
quadrature signals. They also have the capability to double or quadruple
(Quadrature x4) the resolution of the incoming count signal. A separate input
mode is available to make the counter/rate or dual counters completely
independent of each other.

Oneinput provides the signalfor rate or a counterand the other input provides
the signal for a counter. An anti-coincidence add/subtract mode is also provided
to obtain a difference between two input signals.

Each channel features separate scaling and decimal point placement for
readout in different units or at different resolutions.

A Counter Load feature enables the operator to modify the count value under
circumstances that occur when flawed material has been counted and it is
necessaryto adjustthe count valueaccordingly. TheCounter Load featurecan be
“locked out” in applications where it is not required.

The Rate Indicator portion uses a time interval method (1/tau) to calculate the
ratevalue. This method enables high resolution at all rates. The unit counts input
pulses and after a programmable minimum update time has occurred, it waits
until the next edge occurs, takes the elapsed time and number of edges, and
calculates the rate value. At slower rates, averaging can be accomplished by
programming the “Rate Minimum Update Time” (0.5 sec. to 16 sec.) for the
desired response. Extensive scaling capabilities allow practically any desired
reading at very slow count rates.

For maximumflexibility, the Gemini’s output(s) can be assigned to either the
rate or count channels or one to each. When in dual counter mode, the output(s)
can be assigned to the Counter B channel. For the Gemini 4200, one can be
assigned to Counter A and the other to Counter B.

The relay(s) are mounted on a p lug-in board which makes it easy to field
upgradeyourGemini. Thecontacts arerated for240 VACor 28VDC at5 amps.

The construction of the Gemini features a metal, die cast bezel fo r maximum
durability with high quality appearance. The sealed front panel meets NEMA
4/IP65 specifications for washdown and/or dust, when properly installed.
Electrical connections are made with removable, plug-in terminal strips at the
rear of the unit. Clamp-type pressure plate terminals accept stripped #14 AWG
wire without lugs.

SAFETY SUMMARY

All safety related regulations, local codes and instructions that appear in the
manual or on equipment must be observed to ensure personal safety and to
prevent damage to either the instrument or equipment connected to it. If
equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.

Donot use this unit to directly commandmotors, valves, orother actuators not
equipped with safeguards. To do so, can be potentially harmful to persons or
equipment in the event of a fault to the unit.

PROGRAMMING THE GEMINI

When your Gemini arrives from the factory, it has already been programmed
to function as a counter and rate indicator. It is programmed with the factory
settings listed in the “Initial Factory Configuration” section. If it is required to
have the unit operate as two counters, the Unit Personality function code can be
changedtodoso.

The personality, functions, and modes are accessed by pressing the appropriate
keys.A function isdefined by atwo-digit code which appears on the leftside of the
display.The mode of that function is shown as aone-digit code on the right side of
the display. At times there will be a “-” sign modifier to the left of the mode.

Data for the Presets, Scale Factors, Timed Output Values, and Counter Load
Values are entered differently. Each digit key controls the digit on the display
directlyabove it. Changing the digits can be done by repeatedly pressing the key
beneaththe digit positionyou wish tochange or byholding the keydown. As you
holdit down, orrepetitively press it, thevalue of that digit will change cyclically,
countingup to9, then to0, and then up again.The 6 numbered keyscorrespond to
the six digits, and the “+/-” key corresponds to polarity.

PROGRAMMING THE PERSONALITY

Entering function and mode is easily accomplished by
pressingthe appropriate digitkey. For thepersonality function,
you would enter 41 by pressing the front panel keys 4 and 1.

Thedigits on the leftside of the display show the function
code; the digits on the right side show the current
programmed mode.

A mode selection is made by entering a new number . On
someof the entries, you have the option of a plus “+” or minus
“-” sign. In the cases where a “+” sign is required, no sign will
be displayed. If you do enter a “-” sign (using the “+/-” key), a
minus sign will be displayed in front of the appropriate digit.

Pressing the “E” key finalizes the change. The display
will now show the count or rate value immediately.

If you do not press the “E” key, the change will not be
recorded.The display will remainin the programmingmode
for 15 seconds, and then return to normal operating mode
using the old functional mode setting.

Whenever the Unit Personality is changed, the factory settings will
automatically be loaded into the unit. The factory settings can also be
programmedinto theunit by calling upthe Unit Personality, puttinga “-” in front
of the mode by pushing the “+/-” button, and entering it.

Refer to the “Initial Factory Configuration” section for more details.

PROGRAMMING THE PRESET, SCALE FACTORS, TIMED
OUTPUTS & COUNTER LOAD VALUES

The Presets and Scale Factor Values are commonly reprogrammedon a daily
basis. As such, single keystroke access has been provided.

The Gemini has two Scale Factors, one for display A
(Counter A or Rate A), and one for display B (Counter B).
Pressing the “3” key will call up the Scale Factor for the
current display (Rate A/Counter A, or Counter B).

To call up the “other” Scale Factor, the “+/-” key is first pushed to change the
displayto the“other” value, then the “3”key is pushedto displaythe ScaleFactor
for that value.

PROGRAMMING THE PRESET, SCALE FACTORS, TIMED
OUTPUTS & COUNTER LOAD VALUES (Cont’d)

Once the Scale Factor is displayed, changing the digits
canbe accomplished by repeatedly pressing the key beneath
the digit position you wish to change or by holding the key
down, allowing the digit to cycle.

The new value will be entered when the “E” key is
pressed.

The internal count value is multiplied by the Scale Factor Value, which
changesthe displayed value accordingly.It is importantto note thatthe precision
ofan application cannot be improvedby usinga ScaleFactor greater thanone. To
accomplish g reater precision, mo re 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 Scale
Factor of 2.0000, even though the display is reading in tenths. In this case, the
display will increment by two for each count input. Thus, if an odd Preset Value
is entered, such as 6.7 ft., the Gemini will alter the Preset display to read in even
tenths of feet.

To display the Preset 1 Value the “1” key is pushed.

To change the value, the digits can be cycled through in
the same manner as discussed for the Scale Factor. The
preset values can range from -999999 to +999999.

The new value will be entered when the “E” key is

pressed.

The Scale Factor Value will have a direct effect on the preset being entered (if
assigned to the counter). For Scale Factors greater than one, the preset value
should be an integer multiple of the Scale Factor. If it is not, the Gemini will
automaticallyadjust the preset value up or down to force it to be evenly divisible
by the Scale Factor.

The Timed Output 1 or 2 Value is changed by entering a
two-digit function code. After the code is entered, the
display will show the present Timed Output Value in
seconds with two decimal place resolution. The Timed
Output Values can be set from .01 to 599.99 seconds.

Tochange the TimedOutput 1 Value, enterfunction code
53 and enter the new value by holding down or repeatedly
pressingthe keybelow thedigit positionyou wishto change.
The new value will be entered when the “E” key is pressed.
The display will immediately return to the count value.

Note: ATimed Output 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

remain in data entry mode. Ifa new valueis not entered,it will timeout and the

unit will continue to use its previous setting.

As with the other functions, you mustpress “ E” to record thechanges. For the
data entrymodes, if you do not press the “E” key, a time out of 5 seconds occurs,
and the display returns to operating mode without any changes to the value. The
only time any change will occur is when the “E” key is pressed.

It is possible to change the counter values of the Gemini. This feature can be
enabled or disabled by the programming of the “Operator Accessible Functions
Modes”,function code 66.The “Counter LoadValue” is not stored when the unit
ispowered down. When theunit is powered up,the Counter Load valuesfor both
counters(if Dual counter personality) arereset to zero. Once changed, thevalues
will be held until the unit is again powered down.

Toaccess the Counter Load valuefor the desired counter;
first, press the “+/-” key, if necessary, so that the display is
indicating the counter value which is to be changed.

Secondly, press the “E” key and while holding it down,
press the “+/-” key.

TheGemini will now displaythe displayed Counter Load
value. (It will be zero, unless the value had been changed
since the unit was powered up.)

To change the value, press the key under the digit to be
changed as explained previously for the Preset.

To load the value into the counter, press the “E” key.

The display will flash momentarily and will display the
counter with the new value.

INITIAL FACTORY CONFIGURATION DUAL COUNTER FACTORY SETTINGS*

Keys struck Display Description

4,1 41 2 Personality selected as DUAL COUNTER
4,2 42 3 Reset Counters A & B
4,3 43 1 Count with Inhibit
4,4 44 1 Single edge counting (A & B)
4,5 45 1 Counter B Scale multiplier of 1.0
4,6 46 1 Counter B leading zero blanking and no decimal point
5,1 51 2 Outputs 1 & 2 assigned to Counter B
5,2 52 3 Output 1 terminates at Reset, Normal Phase.
5,3 0000.10 Timed Output 1 Value of 0.1 Sec
5,4 54 3 Output 2 terminates at Reset, Normal Phase.
5,5 0000.10 Timed Output 2 Value of 0.1 Sec
5,6 56 1 Counter B, manual reset to zero
6,1 61 1 Counter A, manual reset to zero
6,4 64 1 Counter A scale multiplier of 1
6,5 65 1 Counter A leading zero blanking, no decimal point
6,6 66 1 No functions except Reset enabled

3 01.0000 Scale Factor A set to 1.0000
3 01.0000 Scale Factor B set to 1.0000
1 000500 Preset 1 set to 500
2 001000 Preset 2 set to 1000

* If [41 1] is changed to [41 2], then the factory settings are as shown.

Keys struck Display Description

4,1 41 1 Personality selected as COUNTER/RATE
4,2 42 3 Reset Rate (A) Output(s) & Counter (B)
4,3 43 1 Count with Inhibit
4,4 44 1 Single edge counting (B)
4,5 45 1 Counter B Scale multiplier of 1.0
4,6 46 1 Counter B leading zero blanking and no decimal point
5,1 51 2 Outputs 1 & 2 assigned to Counter (B)
5,2 52 3 Output 1 terminates at Reset, Normal Phase
5,3 0000.10 Timed Output 1 Value of 0.1 Sec
5,4 54 3 Output 2 terminates at Reset, Normal Phase
5,5 0000.10 Timed Output 2 Value of 0.1 Sec
5,6 56 1 Counter (B), manual reset to zero
6,1 61 4 No Rate (A) right hand dummy zeros
6,2 62 1 Rate per Second
6,3 63 1 Rate (A) 0.5 Sec Minimum Update Time
6,4 64 4 Rate (A) Scale multiplier of 1
6,5 65 1 Rate (A) leading zero blanking, no decimal point
6,6 66 1 No functions except Reset enabled

3 01.0000 Scale Factor A (Rate) set to 1.0000
3 01.0000 Scale Factor B (Counter) set to 1.0000
1 000500 Preset 1 set to 500
2 001000 Preset 2 set to 1000

OPERATOR ACCESSIBLE FUNCTIONS WITH
PROGRAMMING DISABLED

(For details on keyboard entry, see preceding section)

One of the important features of the Gemini is the ability to disable
programming.With this ability, accidental bumping of the keys or tampering by
unauthorizedpersonnel can be prevented.However, it maybe necessary to allow
resetand certainprogrammingfunctions, such asPreset and Scale Factor Values,
to be changed in daily operation. The Gemini, through the use of the “Operator
Accessible Functions” Modes can enable these functions even when the “PGM.
DIS.” (Program Disable) terminal is connected to “COMMON”.

The “Operator Accessible Functions” modes are programmed by entering a
two-digit function code (66) and the desired mode. Unlike other function codes,
the mode does not take effect immediately. The “PGM. DIS.” terminal must be
connected to “COMMON” in order for the Gemini to disable programming and
operate as per the mode programmed.

There are six basic “Operator Accessible Functions” Modes available. These
modes enable the following functions.

1. NO FUNCTIONS EXCEPT RESET ENABLED - In this mode, manual

reset is enabled, but none of the programming functions can be changed.

However, the functions can be interrogated.

2. PRESET PROGRAMMING AND RESET ENABLED - Theentirefront

panel is disabled with the exceptions of Preset programmability and manual

reset. All functions can be interrogated.

3. SCALE FACTOR PROGRAMMING AND RESET ENABLED - The

entire front panel is disabled with the exceptions of Scale Factor

programmability and manual reset. All functions can be interrogated.

4. SCALE FACTOR AND PRESET PROGRAMMING, AND RESET

ENABLED - The entire front panel is d isabled with the exceptions of Scale

Factor and Preset programmability, and manual reset. All functions can be

interrogated.

5. PRESET AND COUNTER LOAD PROGRAMMING, AND RESET

ENABLED - The entire front panel is disabled with the exceptions of Preset

and Counter Load programmability. All functions can be interrogated.

6.PRESET, SCALE FACTOR AND COUNTER LOAD PROGRAMMING,
AND RESET ENABLED - The entire front panel is disabled with the
exceptions of Preset, Scale Factor and Counter Load programmability. All
functions can be interrogated.

All of these modes can be modified with the addition of a “-” sign. The minus

sign disables the manual reset, at the front panel and the remote reset (RST., not
RST.A) terminal, at the rear of the unit.

Thereis alsoa rearpanel DIP switchwhich permitsdisabling of thefront panel

reset button. This is independent of the rear terminal remote reset, and can be
used in conjunction with any front panel disable mode. The combination of a
manual and remote reset inputs provides a high level of security without
sacrificing flexibility.

DIAGNOSTICS, SELF-TEST, & “WATCHDOG” TIMER

The security of the Gemini is further enhanced by its self-test diagnostic and

“watchdog” timer capabilities.

The diagnostics are concerned with the special, no power memory of the

Gemini. Whenever the power is turned off, all pertinent function settings and
measurements(except the Counter Load values) are automatically saved. When
power is restored, the functions and data are re-instated. This allows you to
program the unit once and not have to re-program it until you wish to use it in
another mode.

When the function codes and data are saved, computations are made with

thesevalues. The result of these computationsis stored in the memoryto serve as
a check against possible error. On power up the same computations are repeated
on the stored data. If the results do not agree with the stored results, a “P” will
appearon the left side of the display. If this occurs, refer to the “Troubleshooting
Guide” for directions.

DIAGNOSTICS, SELF-TEST, & “WA TCHDOG”TIMER [Cont’d]

Another error indicator is the “watchdog” timer. In order to insure the
software is functioning properly, the program constantly monitors itself. If the
propersequence and timing of internal events does not occur, an “E” will appear
onthe left sideof the display.If this occurs,refer tothe “Troubleshooting Guide”
for directions.

The final type of built-in error checking is the front panel initiated self-test. It
can be performed at any time, even when the Gemini is running. It will not
interferewith theaccumulation o f counts orcontrol functions.A functioncode of
“6”, “+/-” starts the test. At this time, whatever was displayed will disappear and
be replaced by a string of decimal points and the overflow indicator. Then the
displaywill show a string of 9’s, then 8’s etc., until a string of 0’s are shown. The
self-test will then turn off the overflow indicator and activate the minus “-” sign.
Then the unit shows an interlace pattern of -010101, then -212121, followed by
232323 etc., until -898989 is reached. At this time the outputs can be tested by
pressingthe “1” or “2” key. (The program disable terminalmust be disconnected
in order to allow activation of the outputs. Also, when testing the output, use
caution, so as not to cause any undesirable or hazardous conditions in the
system.)An automatic exit will take place after six seconds or immediatelyif the
Program Disable terminal is connected to common. Normal length of display
time for each of the patterns is approximately 0.5 sec. Rapidly pressing “E”
during self-test can speed up the sequence.

INPUT CIRCUITRY & SET-UP

There are two independent input channels on the Gemini. Various types of
sensor outputs can be accommodated by appropriate DIP switch set-up. These
include: TTL or CMOS logic, current sinking, current sourcing, or dry contact
and more.

Channel 1 consists of a logic input and a separate low level magnetic pickup
input.

Channel 2 is a completely independent count or control input channel. Like
Channel 1, it can be programmed with DIP switches for a wide variety of logic
inputs, and is identical to Channel 1 in this regard. For a complete detailed
description of input set-up, see Appendix “A”.

OVERFLOW INDICATION

The Gemini features an overflow indicator (LED) which is located to the left
of thesixth digit and above the polarity annunciator. This LED will turn on if the
capacity of the display (6-digits) is exceeded or if the internal count capacity
(9-digits) is exceeded. Use of extremely small scale multiplier and Scale Factor
Values can cause the internal count capacity to overflow bef ore the displayed
valuewould overflow. It should also be noted thatthe use of RightHand Dummy
Zeros or Scale Factors larger than one could cause the displayed value to
overflow before a v alue of 999,999 (6-digits) is accumulated.

When the capacity of the display is exceeded, the count value will be
maintainedand willbe valid. But if the internal countvalue is exceeded,then this
value may no longer be valid.

The overflow LED can also turn on under certain conditions when the rate
inputfrequency exceeds the maximum3250 cps allowed for a rate update period
of 16 sec. See Code 63 - “Rate Minimum Update Time”.

PROGRAMMING INSTRUCTIONS FOR THE COUNTER/RATE VERSION OFTHE GEM INI 4000

The first part of this section provides d etailed descriptions of the function
command codes for inputs response modes, reset modes, output terminations,
etc.Then, using an actualapplication example, the programming instructions for
a Counter/Rate version will be “walked through”, to give the user a full
understanding of the Gemini programming procedure. The descriptions below
give the function command code first, followed by the individual mode
identifier. The Function Command Code Summary in the appendix, lists all
codes. (Only commands and modes p ertaining to the Counter/Rate personality
will be discussed in this section.)

CODE 41 - UNIT PERSONALITY

The Gemini can be programmed to operate in one of two different
personalities. In each of the two unit personalities, the Gemini operates as a dual
function indicator. The personality selected determineswhether display channel
A will indicate rate o r count. In both personalities, display channel B operates as
a counter.

When the Unit Personality is changed and entered, all modes and data values
(Preset, Scale Factors, function codes etc.) will be automatically loaded with the
factory settings for that personality. If, for any reason during p rogramming, it is
desired to return to the factory settings (while in code 41), the “+/-” key can be
pushed. When the “E” key is pressed the unit will load the factory settings into
the Gemini.

Theprogramming procedure will vary for the two unit personalities. This entire
section deals with the unit programmed as a Counter/Rate indicator, [41 1].

[41 1]COUNTER (B)/RATE(A) -In thismode, displaychannel Afunctions as

a rate indicator and display channel B functions as a counter. See the

“PROGRAMMING INSTRUCTIONS FOR THE GEMINI 4000” section

for details.
[41 2]DUALCOUNTER - In this mode,both display channels, A &B, function

as counters.

CODE 42 - RESET BUTTON & TERMINAL ACTUATION MODES

The “Reset Button & Terminal Actuation Modes” controls the affect that the
reset button and terminal have on the two display channels. Resetting will not
affect the rate d isplay in any manner. If the output(s) is assigned to the rate
channel, activating thereset button or terminal will reset the rate output(s) if that
particularresponse modeis programmed.Resetting counter (B)will always reset
the assigned output(s).

There is a separate “RST. A” terminal, which resets the Rate (A) output when
activated (if output(s) is assigned to rate). It is provided to allow independent
resetting of each channel.

[42 1] RESET RATE (A) OUTPUT(S)
[42 2] RESET COUNTER (B)
[42 3] RESET RATE (A) OUTPUT(S) AND COUNTER (B)

CODE 43 - INPUTS1&2RESPONSE MODES

The Gemini has six different input response modes. They are: Count(1) with
Inhibit(2); Count(1) with Up/Down Control (2); Two input anticoincidence
Add(1)/Subtract(2);Separate Input mode; Quadrature; and Quadrature x4. In all
modes, except [43 4], Input 1 is used by both the counter and rate channels.

[43 1] COUNTWITH INHIBIT- Input 1serves as thecount andrate input. Input

2 serves as the Inhibit input. When Input 2 is low, the counter will ignore the

count signal appearing at Input 1. The rate channel, however, will continue to

indicate the rate of the signal on Input 1.

WhenInput 2is at a high level,the signal appearing on Input1 will be counted.

The “Counter (B) Reset Modes” will determine the count direction. In

applications where the Inhibit function is not actually used, the Input 2

“SRC/SNK” position of the “INPUT CONFIGURATION DIP SWITCH”

should b e set to the “SNK” position to provide a 7.8 Kohm pull-up resistor.

This will set Input 2 to the Non-Inhibit state.

CODE 43 - INPUTS1&2RESPONSE MODES [Cont’d]

[43 2] COUNT WITH UP/DOWN CONTROL - In this mode, count direction

canbe controlledby thesecond input. Input 1 servesas thecount andrate input
and Input 2 serves as the direction control signal input. When Input 2 is at a
highlevel, thecounter willcount up.When Input2 is at a lowlevel, thecounter
will count down. The rate is not affected by the directional control Input 2.

[43 3] TWO INPUT ANTI-COINCIDENCE ADD/SUBTRACT - This mode

effectively separates count pulses which may simultaneously appear at the
two inputs. The Gemini unit processes the count pulses into a string of
time-separated pulses, so the internal counter will not lose any count pulses.
Input 1 serves as the add and rate input (count increments) and Input 2 serves
as the subtract input (count decrements).

[43 4] SEPARATE INPUT - In this mode, the two functions, Counter (B) and

Rate(A) are independently controlled by theinputs. Input 1 serves as the Rate
(A) input and Input 2 serves as the Counter (B) input.

[43 5] QUADRATURE COUNTING - Quadrature counting modes are

primarilyusedin positioning and anti-jitter applications.The reasonthis mode
works is due to the manner in which two pickups are positioned relative to
each other. The signal on Input 2 is a pulse train signal shifted 90° away from
theInput 1signal. Thesetwo signalsare processedby theGemini as follows:
Input 1 serves as the count and rate input, while Input 2 serves as the
quadrature input. For quadrature with single edge counting, the counter will
countin a positive direction when Input 1 is a negative going edge and Input 2
is at a low level. The counter will count in a negative direction when Input1 is
apositive going edgeand Input 2is at alow level. All transitions on Input 1 are
ignored when Input 2 is at a high level. These logic rules provide the basis for
anti-jitter operation which will prevent false counts from occurring due to
back-lash, vibration, chatter, etc.
Whentwo edge counting is used, the quadrature mode works the same as with
single edge counting when Input 2 is low. But when Input 2 is at a high level,
counts at Input 1 are no longer ignored. Instead the logic rules for Input 1 are
complemented,allowing bothedges of Input 1to be counted. Thisdoubles the
effective resolution of the encoded input. The rate indicator will only use the
falling edge of the Input 1 signal, due to the method of rate indication used.

[43 6] QUADRATURE TIMES 4 - This mode takes the quadrature mode, with

two edge counting, one step further. In quadrature times 4, both Input 1 and

Input2 serve as the count or quadrature input, depending on their state. In one

instance, Input 1 will serve as the count input and Input 2 will serve as the

quadrature input. In another instance, Input 1 will be the quadrature input and

Input 2 will be the count input. This enables each edge, positive and negative

going, of both inputs, 1 and 2, to be counted. This results in a resolution four

times greater than in the basic quadrature x1 mode. As in the other modes,

Input 1 is also used for the rate input. The rate indicator will only use the

falling edge of the Input 1 signal, due to the method of rate indication used.

CODE 44 - COUNTER (B) NUMBER OF COUNT EDGES

The counter of the Gemini can be programmed for either single or two edge
(x2) counting. The number of count edges cannot be set when the count mode is
programmedfor quadrature x4 operation. The Gemini will ignore any attempt to
enter function command code 44 when set for quadrature x4.

[44 1] SINGLE EDGECOUNTING (x1) - Theunit counts on the negative going

(falling) edge of the count input signal. The count mode descriptions describe

how each mode uses this method of edge counting.
[44 2]TWO EDGE COUNTING (x2) - This mode is used when doubling of the

count signal input is required. The unit counts on the positive going (rising)

edge of the count input signal, as well as, the negative going (falling) edge.

CODE 45 - COUNTER (B) SCALE MULTIPLIER

Thereare four CounterB Scale Multipliersthat are available.They effectively
divide the internal Count B value by 1, 10, 100, and 1000 respectively, to yield
the displayed Counter B value. Note: Use of a small scale multiplier in
conjunction with a small Scale Factor could cause the internal count value to be
exceeded before the 6-digit display value is exceeded. See “Programming the
Presets, Scale Factors, Timed Outputs & Counter Load Values” section for
more details.

[45 1] x1
[45 2] x0.1
[45 3] x0.01
[45 4] x0.001

CODE 46 - COUNTER (B) DECIMALPOINT & LEADING
ZERO BLANKING

There are six basic modes of decimal point placement for the counter of the
Gemini. The decimal point is placed to the right of the display digit that
corresponds to the mode identifier. (The right most decimal point, digit 1, is
never turned on.) A “-” sign in front of the mode identifier will inhibit leading
zero blanking. The absence of a “-” sign will enable leading zero blanking.

[46 1] 0
[46 2] 0.0
[46 3] 0.0 0 LEADING ZERO
[46 4] 0.0 0 0 BLANKING
[46 5] 0.0000
[46 6] 0.00000

[46 -1] 000000
[46 -2] 00000.0
[46 -3] 0 0 0 0.0 0 LEADING ZERO
[46 -4] 0 0 0.0 0 0 BLANKING INHIBITED
[46 -5] 00.0000
[46 -6] 0.00000

CODE 51 - OUTPUT ASSIGNMENT

The output(s) of the Gemini 4000 can be assigned to either the rate or count
channel. Assigning the output(s) to the rate [5 1 3] will automatically configure
the “Counter (B) Reset Mode” to Reset to Zero, [56 1].

The Gemini 4200 has a Preset tracking feature which allows Preset 1 to track
Preset 2. If Preset tracking is programmed, whenever the Preset 2 value is
changed, the Preset 1 value will also change to maintain the same offset. For
example, if Preset 1 is 100 and Preset 2 is 200, changing Preset 2 to 300 will
automaticallychange Preset 1 to 200, maintaining same 100 unit offset. In o rder
tochange the amount ofoff set, the Preset 1 value is changed. The Preset tracking
feature is programmed by adding a “-” modifier in front of the desired mode.

[51 1] OUTPUT 1 ASSIGNED TO RATE (A), OUTPUT 2 TO COUNTER

(Gemini 4200 only)

[51 2] OUTPUTS 1 & 2 ASSIGNED TO COUNTER (B)
[51 3] OUTPUTS 1 & 2 ASSIGNED TO RATE (A)

[51 -1]
[51 -2]

These modes are identical with the exception

[51 -3]

that Preset Tracking is enabled.

CODE 52 - OUTPUT 1 TERMINATION MODES

The Gemini has six “Output 1 Termination Modes” which control the way
Output 1 will terminate or reset. In all modes, Output 1 will terminate
immediately when the channel to which it is assigned is manually reset.

Forthe Gemini 4200, the Output1 termination modes 1 & 2 are available only
when both outputs are assigned to the Counter (B), [51 2].

A reverse phase mode is available on the Gemini. This refers to the
complementing of the logic state of the output. With normal phase operation,
when the display value reaches Preset 1, Output 1 will turn on. The reset
conditionof Output 1 is outputoff. In reverse phase operation,Output 1 turns off
when the Preset 1 Value is reached. The reset condition of Output 1 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 indicate normal phase operation.

CODE 52 - OUTPUT 1 TERMINATION MODES (Cont’d)

[52 1] TERMINATE AT OUTPUT 2 START - Output 1 will terminate when

Output2 starts.Output 1is setfor normalphaseoperation. (Gemini4200 Only)

[52 2] TERMINATE AT OUTPUT 2 END - Output 1 will terminate when

Output2 ends.Output 1is setfor normalphaseoperation. (Gemini4200Only)

[52 3] TERMINATE AT MANUAL RESET - Output 1 activates when the rate

or count, whichever it is assigned to, is greater than or equal to the Preset 1
Value.In this mode, once Output 1 is activated, it does not deactivate until the
moment a reset occurs. Output 1 is set for normal phase operation.

[52 4] TERMINATE AT MANUAL RESET END - This mode is like the

preceding, except Output 1 deactivates when reset ends. Output 1 is set for
normal phase operation.

[52 5] TERMINATE AFTER TIMED OUTPUT 1 - Once Outp u t 1 has been

activated, it will deactivate after the predetermined length of time (code 53)
has expired. Manual reset will override the timed output and reset Output 1.
Output 1 is set for normal phase operation.
When Output 1 alone is assigned to the rate [51 1], the output will activate
whenthe rate is greater than or equal tothe Preset 1 Value. When both outputs
areassigned to Rate [51 3], Output 1will act as an “underspeed” detect. It will
activate when the rate is less than or equal to the Preset 1 Value. Output 1 will
activate every update time period for which the above conditions are true. If
the Timed Output 1 Value, code 53, is greater than the rate update time, the
outputwill appear to be latched on,deactivating when therate dropsbelow the
Preset and the output time expires.

[52 6] BOUNDARY MODE - When in boundary mode, the Preset 1 Value

serves as the boundary point. When the display value (count or rate) is less
than the Preset 1 Value, Output 1 is not activated (normal phase). When the
display value is greater than or equal to the Preset 1 Value, Output 1 is
activated. If the display value were to drop below Preset 1, Output 1 would
then deactivate. For negative Preset points, Output 1 is not activated when the
count value is more positive than the Preset 1 Value. When the count is more
negative than (only possible with counter) or equal to Preset 1, Output 1 is
activated. If the count becomes more positive than the Preset 1 Value, the

output again deactivates. When Output 1 is assigned to the counter and the

Preset 1 value is changed, Output 1 will immediately go to the proper state.

Uponpower up,Output 1, if assigned toCounter B, will“remember”its power

down boundary condition and go to that state. Output 1 is set for normal

phase operation.

[52 -1]
[52 -2]
[52 -3] These modes are the same as above with the exception
[52 -4] that the output is set for reverse phase operation.
[52 -5]
[52 -6]

CODE 53 - TIMED OUTPUT 1 VALUE

TheGemini has the capability of varying the Timed Output 1 Value from 0.01
second to 599.99 seconds. When the code is entered, instead of a single mode
identifierdigit being displayed, six digits will be shown. Refer to “Programming
the Presets, Scale Factors, Timed Outputs & Counter Load Values” section for
more details about entering. The timed output will be terminated if the unit is
manually reset.

The Timed Output 1 Value is used only when in Timed Output 1 Termination
mode, [52 5].

Note: ATimed Output 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

not enter the 0, but will stay in the data entry mode. If a new value is not

entered, it willtime out and the unitwill continue touse its previous setting.

CODE 54 - OUTPUT 2 TERMINATION MODES (GEMINI 4200
Only)

The Gemini 4200 has six “Output 2 Termination Modes” which control the
way Output 2 will terminate or reset. In all modes, Output 2 will terminate
immediately when the channel to which it is assigned is manually reset.

Output 2 termination modes 1 & 2 are available only when both outputs are
assigned to the Counter (B), [51 2].

A reverse phase mode is available on the Gemini 4200. This refers to the
complementing o f the logic state of the output. With normal phase operation,
when the display value reaches Preset 2, Output 2 will turn on. The reset
conditionof Output 2 is outputoff. In reverse phase operation,Output 2 turns off
when the Preset 2 Value is reached. The reset condition of Output 2 is output on.
(Note: The state of the relay, if u sed, is also reversed.) A “-” sign in front of the
mode identifier will provide for reverse phase operation. The absence of a “-”
sign will indicate normal phase operation.

[54 1] TERMINATE AT OUTPUT 1 START - Output 2 will terminate when

Output 1 starts. Output 2 is set for normal phase operation.
[54 2] TERMINATE AT OUTPUT 1 END - Output 2 will terminate when

Output 1 ends. Output 2 is set for normal phase operation.
[54 3] TERMINATE AT MANUAL RESET - Output 2 activates when the rate

or count, whichever it is assigned to, is greater than or equal to the Preset 2

Value.In this mode, once Output 2 is activated, it does not deactivate until the

moment a reset occurs. Output 2 is set for normal phase operation.
[54 4] TERMINATE AT MANUAL RESET END - This mode is like the

preceding, except Output 2 deactivates when reset ends. Output 2 is set for

normal phase operation.
[54 5] TERMINATE AFTER TIMED OUTPUT 2 - Once Output 2 has been

activated, it will deactivate after the predetermined length of time (code

55) has expired. Manual reset willoverride thetimed output and resetOutput

2. When assigned to count or rate, Output 2 will activate when the display

valueis greater than or equal to the Preset 2 Value. Output 2 is set for normal

phase operation.
[54 6] BOUNDARY MODE - When in boundary mode, the Preset 2 Value

serves as the boundary point. When the display value (count or rate) is less

than the Preset 2 Value, Output 2 is not activated (normal phase). When the

display value is greater than or equal to the Preset 2 Value, Output 2 is

activated. If the display value were to drop below Preset 2, Output 2 would

then deactivate. For negative Preset points, Output 2 is not activated when the

count value is more positive than the Preset 2 Value. When the count is more

negative than (only possible with counter) or equal to Preset 2, Output 2 is
activated. If the count becomes more positive than the Preset 2 Value, the
output again deactivates. When Output 2 is assigned to the counter and the
Preset 2 value is changed, Output 2 will immediately go to the proper state.
Uponpower up,Output 2, if assigned toCounter B, will“remember”its power
downboundary condition and go to that state. Output 2 is set for normalphase
operation. Programming Boundary mode will automatically select [56 1], if
[51 1 or 2] is programmed.

[54 -1]
[54 -2]
[54 -3] These modes are the same as above with the exception
[54 -4] that the output is set for reverse phase operation.
[54 -5]
[54 -6]

CODE 55 - TIMED OUTPUT 2 VALUE (GEMINI 4200 Only)

TheGemini 4200has the capabilityof varying theTimed Output2 Value from

0.01 second to 599.99 seconds. When the code is entered, instead of a single
mode identifier d igit being displayed, six digits will be shown. Refer to
“Programming the Presets, Scale Factors, Timed Outputs & Counter Load
Values” section for more details about entering. The timed output will be
terminated if the unit is manually reset.

The Timed Output 2 Value is used only when in Timed Output 2 Termination

mode, [54 5].

Note: A Timed Output Value of zero cannot be programmed into the Gemini

4200. If a value of 0 is entered into the display and the “E” key is pressed, the
unit will not enter the 0, but will stay in the data entry mode. If a new value is
not entered itwill time out and theunit will continueto use its previous setting.

CODE 56 - COUNTER (B) RESET MODES

The Gemini 4000 has six different counter reset modes. There are also two
methodsby which manualreset can acton the counter (resetmust be enabled, see
function code 66 and dip switch set-up). The first is a “maintained” reset action,
where the unit is held at reset for as long as the reset terminal or reset button is
activated.The secondis a “momentary”reset, inwhich the unit resets, whenreset
isactivated, and starts countingeven though the terminalor reset buttonmay still
be active. A “-” sign in front of the mode identifier indicates “momentary” reset
action, the absence of the “-” sign indicates “maintained” reset action.

For the Gemini4200, if both outputs are assigned to the Rate Channel [51 3],
orthe Output2 Terminationmode isboundary [54 6], the only Counter (B)Reset
mode that is available is Reset to Zero [56 1].

In Reset to Zero modes the Output (if assigned to Counter B) activates at the
Preset Value. In Reset to Preset modes the Output activates at zero.

In the “Reset to Preset” modes, for proper operation, the counter normally
counts down. In the “Count with Inhibit” and “ Separate Inputs” input response
modes, [43 1 or 4], the unit will automatically count down if a Reset to Preset
mode is selected. In the other input response modes, proper input phasing is
required for down counting. See “CODE 43 - INPUTS 1 & 2 RESPONSE
MODES” section for more details.

Note: The Reset Button & Terminal Actuation Mode must be programmed to

mode [42 2 or 3] in order to be able to manually reset the Counter (B). The

activation and de-activation response time for reset is 10 msec.
Note: For the Gemini 4200, all reset to preset modes reset to preset 2and Timed

Output refers to Output 2.

[56 1] MANUAL RESET TO ZERO (RTZ) - Manual reset to zero is

accomplished by pulling the “RST.” terminal to “COMMON” or, if the front

panel reset is enabled, by pressing the front panel reset button. Reset is

“maintained”.
[56 2] MANUAL RESET TO PRESET (RTP) - Manual reset to Preset is

accomplished by pulling the “RST.” terminal to “COMMON” or, if the front

panel reset is enabled, by pressing the front panel reset button. Reset is

“maintained”.

[56 3] AUTOMATIC RESET TO ZERO AFTER TIMED OUTPUT - The

counter automatically resets to zero when Timed Output ends. Manual reset
is “maintained”and will override automatic reset. The “Output Termination
Mode” should be programmed for timed output operation, [54 5], when in
this mode.

[56 4] AUTOMATIC RESET TO PRESET AFTER TIMED OUTPUT - The

counter automaticallyresets to Preset when TimedOutput ends. Manual reset
is “maintained” and will override automatic reset.

The “Output Termination Mode” should be programmed for timed output

operation, [54 5], when in this mode.
[56 5] AUTOMATIC RESET TO ZERO AT BEGINNING OF TIMED

OUTPUT (AT PRESET) - In this reset mode, the counter will automatically
reset to zero at the beginning of Timed Output (at Preset). The Timed Output
Value must be shorter than the time required for the counter to count to the
PresetValue, otherwise, the Output will appear to be latched on. Manual reset
is “maintained” and will override automatic reset. The “Output Termination
Mode” should be programmed for timed output operation, [54 5], when in
this mode.

[56 6] AUTOMATIC RESET TO PRESET AT BEGINNING OF TIMED

OUTPUT(AT ZERO)- In this reset mode,the counterwill automaticallyreset
to Preset at the beginning of Timed Output (at zero).The Timed Output Value
must be shorter than the time required for the counter to count to zero,
otherwise, the Output will appear to be latched on. Manual reset is
“maintained” and will override automatic reset. The “Output Termination
Mode” should be programmed for timed output operation, [54 5], when in
this mode.

[56 -1]
[56 -2]
[56 -3] These modes are the same as above with the exception
[56 -4] that manual reset is set for “momentary” operation.
[56 -5]
[56 -6]

CODE 61 - RATE (A) RIGHT HAND DUMMY ZEROS

Dummy zeros can be used to alleviate display fluctuations due to an unstable
inputsignal. Thesezeros effectivelymove significantdigits tothe left.Therefore, a
normal count of 1 could be shown as a 10, 100, or 1000. Using the dummy zeros
will make it necessary to adjust the scaling if they were not considered before.

[61 1] 1 RIGHT HAND DUMMY ZERO
[61 2] 2 RIGHT HAND DUMMY ZEROS
[61 3] 3 RIGHT HAND DUMMY ZEROS
[61 4] NO RIGHT HAND DUMMY ZEROS

CODE 62 - RATE CONVERSION FACTOR

Therate conversion factorprovides a simplemeans of obtainingthe desired rate
reading,using the same Scale FactorValue as the counter, when the rateand count
units are the same. In most applications, it is simply programmed to the desired
time unit that the rate is to displayed in. See Appendix “F” - Scaling For Rate.

[62 1] Rate Per Second (x1)
[62 2] Rate Per Minute (x60)
[62 3] Rate Per Hour (x3600)

CODE 63 - RATE MINIMUM UPDATE TIME

The determination of the rate value uses a method in which the elapsed timeis
measured between the first and last pulse of the update period. The minimum
updatetime is theshortest the timeperiod can be. Once the minimumupdate time
has expired, the unit will end the measurement period when the next negative
goingcount edge occurs.If the unitdoes not receive the next negative countedge
within the maximumupdate time at the start of the measurement period, the unit
will end the time period and the rate display will go to zero. At very slow count
rates the update time period will be the actual period of one count cycle.

[63 1] 0.5 Sec. minimum/1 Sec. maximum
[63 2] 1 Sec. minimum/2 Secs. maximum
[63 3] 2 Sec. minimum/4 Secs. maximum
[63 4] 4 Sec. minimum/8 Secs. maximum
[63 5] 8 Sec. minimum/16 Secs. maximum (max. rate = 7500 cps)
[63 6] 16 Sec. minimum/32 Secs. maximum (max. rate = 3250 cps)

CODE 64 - RATE SCALE MULTIPLIER

The Rate Scale Multiplier is used in conjunction with the Rate Scale Factor A
and Rate Conversion Factor to scale the actual signal input to obtain the desired
reading. See Appendix “ F” - Scaling For Rate.

[64 1] x 1000
[64 2] x 100
[64 3] x10
[64 4] x1
[64 5] x0.1
[64 6] x0.01

CODE 65 - RATE (A) DECIMAL POINT & LEADING ZERO
BLANKING

Thereare six basic modes of decimalpoint placement for the Rate indicator of
the Gemini. The decimal point is placed to the right of the display digit that
corresponds to the mode identifier. (The right most decimal point, digit 1, is
never turned on.) A “-” sign in front of the mode identifier will inhibit leading
zero blanking. The absence of a “ -” sign will enable leading zero blanking.

[65 1] 0
[65 2] 0.0
[65 3] 0.0 0 LEADING ZERO
[65 4] 0.0 0 0 BLANKING
[65 5] 0.0000
[65 6] 0.00000

[65 -1] 000000
[65 -2] 00000.0
[65 -3] 0 0 0 0.0 0 LEADING ZERO
[65 -4] 0 0 0.0 0 0 BLANKING INHIBITED
[65 -5] 00.0000
[65 -6] 0.00000

CODE 66 - “OPERATOR ACCESSIBLE FUNCTIONS” MODES

The Gemini has six b asic levels of “Operator Accessible Functions”. Each of
these levels can be modified to enable or disable manual reset. When the “PGM.
DIS.” (Program Disable) terminal is connected to “COMMON”, access to all
functionsis disabledexcept for those listed belowwhich willremain enabled.All
of the function codes and parameters can be interrogated, regardless of the
“Operator Accessible Functions” mode selected.

A “-” sign in front of the mode identifier will disable the front panel Reset
button and the “RST.” terminal.

Note: The front panel reset button can be independently disabled by using the

disable reset DIP switch.

[66 1]NO FUNCTIONS ENABLED EXCEPT RESET - In this mode, manual

reset is enabled, but none of the programming functions can be changed.
[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,manualreset andthe programmingofthe ScaleFactor Valuesare 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.
[66 5] PRESET, COUNTER LOAD PROGRAMMING AND RESET

ENABLED - In this mode, manual reset and the programming of the Presets

and Counter Load Value are enabled.
[66 6] PRESET, SCALE FACTOR, COUNTER LOAD PROGRAMMING

ANDRESET ENABLED -In this mode, manualreset andthe programmingof

the Presets, Scale Factors and Counter Load Value are enabled.

[66 -1]
[66 -2]
[66 -3] These modes are the same as above with the
[66 -4] exception that manual reset is disabled.
[66 -5]
[66 -6]

PRESET VALUE

Whenever the display value equals the preset value (when output is assigned
to that display channel), an output action will occur. This action depends on the
previously programmed modes. The preset values may range from -999,999 to
999,999. (Refer to “Programming the Presets, Scale Factors, Timed Outputs &
Counter Load Values” section for instructions on entering the preset values.)

TheCounter (B)Scale Factor,SFB, willhave adirect effecton thepreset value
being entered (if assigned to the counter). For a Scale Factor Value greater than
one,the preset value should be an integer multipleof the Scale Factor. If it is not,
the Gemini will automaticallyadjust the preset value up or down to force it to be
evenly divisible by the Scale Factor.

“1” - PRESET 1 VALUE
“2” - PRESET 2 VALUE (GEMINI 4200 Only)

SCALE FACTORS A & B

“3” SCALE FACTOR - The Scale Factor, for which value (count or rate) is
currently being displayed, is accessed b y pressing the “3” key. To access the
Scale Factor of the “other” display v alue, the “+/-” key would be pushed (to
change the display to the other value), then the “3” key would be pushed.

Thenumber of pulses counted (internal count value) ismultiplied by theScale
Factor, which changes the displayed value accordingly. A Scale Factor Value of

1.0000 would result in a display of the actual number of input pulses that have
been counted. The Scale Factor is used primarily for conversion from existing
pulses per unit of measure to the required displayed units. This includes
conversion from different units of measure (i.e feet to meters, etc.).

TheScale FactorValues mayrange from-5.9999 to +5.9999 (positive onlyfor
Rate (A) Scale Factor, SFA). Refer to “ Programming the Presets, Scale Factors,
Timed Outputs & Counter Load Values” section for entering instructions. It is
important to note that the precision of a counter application cannot be improved
by using a Scale Factor greater than one. To accomplish greater precision, more

pulseinformation mustbe generated per measuringunit. 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 Scale Factor of 2.0000, even though the
displayis readingin 10ths. In this case,the displaywill incrementby two foreach
count input. Thus if an odd Preset Value was entered, such as 6.7 ft., the Gemini
will alter the preset to read in even tenths of feet.

Note: Use of a small Scale Factor in conjunction with a small scale multiplier

could cause the internal count value (counter) to be exceeded before the
6-digit display value is exceeded.

COUNTER LOAD VALUE

The Counter Load Value is provided to allow the user to modify the count
value. The Counter Load Value is reset to zero when the Gemini is powered up.
Once the Counter Load Value has been changed, it will remain set to that value
untilthe unit is powered down and up. Accessing the Counter LoadValue for the
counter that is currently being displayed is accomplished by pushing the “E”
button, and while holding it down, also pushing the “+/-” button. See
“Programming the Presets, Scale Factors, Timed Outputs & Counter Load
Values” section for entering instructions.

“E” & “+/-” - Counter Load Value for the currently displayed counter.

DUAL PRESET COUNTER & RATE APPLICATION

A wire screen manufacturer requires a cut to length system, and in addition, a
prewarning of an overspeed condition. The cutting machine is equipped with an
existing 12 tooth gear, driving a one foot circumference feed roller.

The Gemini 4200’s counter is to read in feet. When 15,000 feet has been
accumulatedon thetake uproll, the counteroutput isto turn onand deactivatethe
drive system. The operator will then make the cut, load a new take up roll and
reset the Gemini to start a new roll.

In addition to cut to length, the same Gemini 4200 is to be used to indicate the
speed of the wire screen in feet per minute, while providing a “overspeed”
warning. The normal running speed of the material is 225 feet per minute. The
maximum allowable speed of the process is 250 feet per minute.

HARDWARE SETUP

The accompanying drawing shows how the hardware is setup for this
application. A Model PSAC proximity sensor is used to sense the teeth on the
gear. The application does not require bi-directional counting, so the Gemini
4200 will be programmed for the Count with Inhibit “Inputs 1 & 2 Response
Mode”. In this mode, both the rate indicator and counter will utilize the same
input signal. The switch settings and the wiring connections are as shown. The
Input 2 switch positions 5-7 are set to put the Input 2 in the non-inhibit state with
maximum noise immunity.

SCALING THE COUNTER

In order to scale the counter, the procedure and formulas in Appendix “E” ­Scaling for Counting are used.

In converting pulse units to “Display Units”, it is known that 12 pulses are
equivalent to 1 revolution of the feed roll, which is equivalent to 1 foot linear
travelof thewire screen. The “Display Unit”,therefore is1 foot andthe “Number
of Pulses” per display unit is 12.

STEP 1 - Calculate the Total Scaling Factor, “K

T

”, using Formula #1 of

Appendix “E”.

K

T

= Display Unit / Number of Pulses

K

T

= 1/12 = 0.083333

STEP 2 - Determine the Number of Count Edges, “NCE”, necessary for this

application, and calculate the Remaining Scaling required, “K

R

”, using
Formula #2 of Appendix “E”.
Since the Total Scaling Factor, “K

T

”, is less than 1, single edge counting can

be used, therefore, the Number of Count Edges, “NCE”, is 1.

K

R=KT

/NCE

K

R

= 0.083333/1 = 0.083333

STEP3 -Determine the Scale Multiplier Value, “SCM”, and calculate the Scale

Factor, “SF”, using Formula #3 of Appendix “E”.
A Scale Multiplier v alue of 0.1 is chosen to provide the maximum number of
significant digits in the Scale Factor.

SF = K

R

/SCM

SF = 0.083333/0.1 = 0.8333

SCALING THE RATE INDICATOR

In this application the rate indicator can be programmed with the same scale
factorand scale multiplier values asobtained when scaling the counter. The only
other scaling that would be required is choosing the proper Rate Conversion
Factor,to obtainthe display in the desiredtime units.The applicationcalls for the
rate to be indicated in feet per minute, therefore, the Rate Per Minute Rate
Conversion Factor is selected.

STEP BY STEPPROGRAMMING OF THE GEMINI 4200

STEP 1 - Enter code 41 (Unit Personality). Select and enter a mode identifier of

1, for the Gemini to operate as a Counter and Rate indicator.
STEP2 - Enter code 42 (ResetButton & Terminal Actuation Modes).Select and

enter mode 2 to reset the counter when reset is activated.
STEP3 -Enter code 43(Inputs 1& 2 ResponseModes). Selectand enter mode1,

“Count with Inhibit”.
STEP 4 - Enter code 44 (Counter B Number of Count Edges). Select and enter

mode 1 for single edge counting.
STEP5 -Enter code45 (Counter BScale Multiplier).Select and entermode 2for

a scale multiplier of 0.1.
STEP 6 - Enter code 46 (Counter B Decimal Point & Leading Zero Blanking).

Select and enter mode 1 for no decimal point.
STEP 7 - Enter code 51 (Output Assignment). Select and enter mode 1 to assign

Output 1 to the rate indicator and Output 2 to the counter.
STEP8 - Enter code 52 (Output 1 TerminationModes). Select and enter mode 6

for boundary operation. Output 1 will activate when the maximum speed

value, Preset 1, is exceeded. Output 1 will deactivate when the rate decreases

to a value below the maximum speed.

Note: The Timed Output 1 Value, code 53, is not used in this application.

STEP9 - Enter code 54 (Output 2 TerminationModes). Select and enter mode 4

for Output 2 Terminate at Manual Reset.

Note: The Timed Output 2 Value, code 55, is not used in this application.

STEP 10 - Enter code 56 (Counter B Reset Modes). Select and enter mode 1 for

manual reset to zero.

STEP 11 - Enter code 61 (Rate Right Hand Dummy Zeros). Select and enter

mode 4 for no right hand dummy zeros.

STEP12 - Entercode 62 (Rate ConversionFactor). Select and entermode 2 fora

Rate Per Minute conversion factor.

STEP13 - Entercode 63 (Rate MinimumUpdate Time).Select and entermode 1

for a minimum update time of 0.5 Second. If the rate display jumps around, a
larger minimum update time can be used to provide averaging.

STEP 14 - Enter code 64 (Rate Scale Multiplier). Select and enter mode 5 for a

Scale Multiplier of 0.1, as previously d etermined.

STEP15 - Enter code 65 (Rate DecimalPoint & Leading Zero Blanking). Select

and enter mode 1 for no decimal point.

STEP 16 - Enter code 66 (Operator Accessible Functions Modes). Select and

entermode (+)1 for no functions except reset enabled.When the “PGM.DIS.”
terminal is connected to “COMM.”, the only changes that will be possible is
resetting the counter.

STEP17 -The “+/-”key ispushed, ifnecessary, sothat therate isbeing indicated

on the Gemini 4200. The “3” key is then pushed to call up the Rate Scale
Factor. The value is changed to 0.8333.

STEP 18 - The “+/-” key is pushed, so that the count is being indicated on the

Gemini 4200. The “3” key is then pushed to call up the Counter Scale Factor.
The value is changed to 0.8333.

STEP19 - Entera Preset1 value of 250,by pushing the“1” key andchanging the

value to 250.

STEP20 - Enter aPreset 2 value of15,000, by pushing the “2” key and changing

the value to 15,000.
After the unit is programmed, the “PGM. DIS.” terminal is connected to
“COMM.” to p revent any unauthorized or accidental mode changes. The
function codes can, however, be called up to view or verify that the proper
modes are entered.

PROGRAMMING INSTRUCTIONS FOR THE DUALCOUNTER VERSIONOF THEGEMINI 4000

The first part of this section provides d etailed descriptions of the function
commandcodes for input response modes, reset modes,output terminations, etc.
Then, using an actual application example,the programming instructions for the
Dual Counter version will be “walked through”, to give the user a full
understanding of the Gemini 4000 programming procedure. The descriptions
below give the function command code first, followed by the individual mode
identifier. The Function Command Code Summary in the appendix, lists all
codes. (Only commands and modes pertaining to the Dual Counter personality
will be discussed in this section.)

CODE 41 - UNIT PERSONALITY

The Gemini can be programmed to operate in one of two different unit
personalities. In each of the two personalities the Gemini operates as a dual
function indicator. The personality selected determineswhether display channel
A will indicate rate o r count. In both personalities, display channel B operates as
a counter.

When the Unit Personality is changed and entered, all modes and data values
(Presets, Scale Factors, function codes, etc.) will be automatically loaded with
thefactory settings for thatpersonality. If, for anyreason during programming,it
is desired to return to the factory settings, the “+/” key can be pushed while in
code 41. Then, when the “E” key is pressed the unit will load the factory settings
into the Gemini.

The programming procedures for the two unit personalities will vary. This
entiresection dealswith theunit programmedasa DualCounter indicator,[41 2].

[41 1]COUNTER(B)/RATE(A) -In thismode, displaychannel Afunctions asa

rate indicator and display channel B functions as a counter. See

“PROGRAMMING INSTRUCTIONS FOR COUNTER/RATE VERSION

OF THE GEMINI” section for details.
[41 2] DUAL COUNTER - In this mode, both display channels {A & B}

function as counters.

CODE 42 - RESET BUTTON & TERMINAL ACTUATION
MODES

The “Reset Button & Terminal Actuation modes” control the affect that the

reset button and terminal have on the two display channels.

There is a separate “Rst A” terminal which resets Counter A, when activated.

It is provided to allow independent resetting of each channel.

[42 1] RESET COUNTER A
[42 2] RESET COUNTER B
[42 3] RESET COUNTER A & B

CODE 43 - INPUTS1&2RESPONSE MODES

The Gemini has six different input response modes. They are: Count(1) with
Inhibit(2); Count(1) with Up/Down Control (2); Two input anticoincidence
Add(1)/Subtract(2);Separate Input mode; Quadrature; and Quadrature x4. In all
modes, except [43 4], both counters will respond identically to both inputs.
These modes are most suitable for applications where one channel is used for
control, and the other for totalizing counts.

[43 1] COUNTWITH INHIBIT- Input1 serves asthe countinput. Input 2 serves

as the Inhibit input. When Input 2 is low, the counters will ignore the count

signal appearing at Input 1. When Input 2 is at a high level, the pulses

appearing at Input 1 will be counted.
[43 2] COUNT WITH UP/DOWN CONTROL - In this mode, count direction

can be controlled by the second input. Input 1 serves as the count input and

Input 2 serves as the direction control signal input. When Input 2 is at a high

level, the counters will count up. When Input 2 is at a low level, the counters

will count down.
[43 3] TWO INPUT ANTICOINCIDENCE ADD/SUBTRACT - This mode

effectively separates count pulses which may simultaneously appear at the

two inputs. The Gemini unit processes the count pulses into a string of

time-separatedpulses, so the internalcounters willnot lose anycounts. Input1

serves as the add input (count increments) and Input 2 serves as the subtract

input (count decrements).