Red Lion GEMINI 2 User Manual

THE ASTRO LINE SERIES

GEMINI 1000/2000 INSTRUCTION MANUAL

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.

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: Read complete instructions prior

to installation and operation of the unit.

CAUTION: Risk of electric shock.

TABLE OF CONTENTS

I. GENERAL DESCRIPTION

Safety Summary................................................... 2

Programming The Gemini 1000/2000 ........................................ 2-3

Programming The Personality............................................ 3

Programming The Presets, Scale Factor, & Output Time Delays.......................... 3-4

Factory Settings ................................................... 5

Operator Accessible Functions With Programming Disabled ............................ 6

Diagnostics, Self-Test, & “Watchdog” Timer .................................... 6-7

Input Circuitry & Set-up ............................................... 7

Overflow Indication ................................................. 7

II. PROGRAMMING INSTRUCTIONS FOR THE COUNTER VERSION OF THE GEMINI 1000/2000........ 8-13

Codes 41, 43, 44, 45, & 46 ............................................. 8-9

Codes 51, 52, 53, 54, & 55 ............................................. 9-12

Codes 61, 66, Preset Values, & Scale Factor ................................... 12-13

Dual Preset Counting & Programming Application Example ............................ 14-15

III. PROGRAMMING INSTRUCTIONS FOR THE RATE INDICATOR VERSION OF THE GEMINI 1000/2000 . . . 16-21

Codes 41, 44, 45, & 46 ............................................... 16

Codes 51, 52, 53, 54, & 55 ............................................. 16-18

Codes 61, 63, 66, Preset Values, & Scale Factor.................................. 8-19

Dual Preset Rate Programming Application Example................................ 20-21

IV. 20 mA CURRENT LOOP SERIAL COMMUNICATIONS (GEMINI 2000 ONLY) ................. 22-29

Communication Format ............................................... 22

Sending Commands & Data To The Gemini 2000 ................................. 22-23

Receiving Data From The Gemini 2000....................................... 24

Print Options .................................................... 24

Current Loop Installation .............................................. 25-26

Communications Application ............................................ 27

Troubleshooting Gemini Serial Communications .................................. 28

Serial Loop-Back Self-Test ............................................. 28

V. APPENDIX “A” - INSTALLATION & INPUT CONFIGURATION SWITCH SET-UP ............... 29-39

VI. APPENDIX “B” - SPECIFICATIONS & DIMENSIONS .............................. 40-41

VII. APPENDIX “C” - TROUBLESHOOTING GUIDE ................................ 42-44

VIII. APPENDIX “D” - FUNCTION COMMAND CODE SUMMARY ......................... 45-47

IX. APPENDIX “E” - SCALING FOR RATE INDICATION .............................. 48-49

X. APPENDIX “F” - GEMINI 1000/2000 PROGRAMMING CHARTS ........................ 50-53

XI. APPENDIX “G” - ORDERING INFORMATION .................................. 54

–1–

GENERAL DESCRIPTION

The Geminiis a two input,microprocessor-based device whichoffersthe features and performance of a single (GEM 1000)/dual (GEM 2000) level preset counter or sample time, rate indicator. The 6-digit display features 0.56" LEDs with negative sign and overflow indicators. The internalprecision is maintained to 9 digits. The 20 mA Current Loop Option (Gemini 2000 only) makes possible remote or computerized monitoring or control of the count, Presets and Scale Factor.

Flexibility and usefulness are insured through user programmability. With simple front panelkeystrokes and rear panelswitch settings, any oneof a number 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. All set-up data is stored in

PROM, which will hold data for a minimum of 10 years without power.

Whenever the power comes on, the Gemini performs a series of internal diagnostics to verify the integrity ofthe stored data. Thereis also a self-testmode and an ever-present “watchdog” timer to prevent processor lockup.

The construction of the Gemini features a metal, die cast bezel for maximum durability with high quality appearance. The sealed front panel meets NEMA 4/IP65 specifications forwashdownand/or dust. Electrical connectionsare 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.

As a counter,the Gemini can monitor bi-directional, unidirectional(totalizer), or quadrature signals. It can double or (with quadrature) even quadruple the resolution of the incoming signal. Counting modes also provide for anti-coincidence applications. Bothchannels of count information aremonitored simultaneously, no counts are lost, and the final output can be chosen as the sum or difference of the two input channels.

As a rate indicator, a variety of sampling times are available. Accurate to one hundredth of a percent,the sampling time can be setas 1, 2, 5, 10, 20, or50 seconds.

The preset level(s) can be selected to control an open collector output(s). The optional Gemini plug-in relay board makes it easy to field upgrade your Gemini to provide 5amp,240 VAC relay output(s).Theoutput(s) are also programmable and can be set for terminate at the “other” output start, “other” output end, at reset or reset end, after time delay, or boundary.

Preset and reset behavior of the output(s) and display are completely programmable. The preset(s) canhave a value ranging from -999999 to +999999. Decimal placement will bethe sameas the decimal placement on the inputvalue.

Various resetmodes can be selected: manualreset 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.

The scale factor, moveable decimal point, dummy right hand zeros, leading zero blanking, and decade divider capabilities of the Gemini permit complete control of the Gemini display. These features provide easy conversion of input signals to desired measurement units (feet to meters, etc.). The input values can be multiplied by any number from -5.9999 to +5.9999 with the scale factor. The addition of up to 3 dummy right hand zeroes gives an effective display multiplication of 10, 100, or 1000. Similarly, the decade divider provides 1, 2, or 3 decades of prescaling.

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.

Do notuse this unit todirectly command motors,valves, or other 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 preset counter.

The personality,functions, and modes are thenset by pressing the appropriate keys. A function is defined by a two-digit code which appears on the left side of the display. The mode of that function is shown as a one-digit code on the right side of the display. At times there will be a (-) sign modifier.

–2–

Data forthe presets, scalefactor, and time delays are entered differently. Each digit key controls the digit on the display directly above it. Changing the digits can bedone by repeatedly pressing the key beneath thedigit position you wish to change orby merely holding it down. As youhold it down or press it, thevalue of that digit will change cyclically, counting up to 9, then to 0, and then up again.

The 6 numbered keys correspond to the six digits, and the “+/-” key correspond to polarity.

PROGRAMMING THE PERSONALITY

Entering function and mode is easily accomplished by pressing the appropriate digit key. For the personality function, enter 41 by pressing the front panel key 4.

Then press the front panel key 1. The leftmost LEDs show the function; the rightmost is the present mode.

A new mode selection is made by entering a new number. On some of 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 remain for 15 seconds, and then return to normaloperating mode using theold function and mode settings. (Note: The reset button “R”, if enabled, is

always active. Pressing reset will immediately abort the function selection, and reset the instrument.)

The major personality is function code 41. If it is changed from rate to counter or vice-versa, it may effect settings like count mode, reset mode, and output termination modes.

PROGRAMMING THE PRESETS, SCALE FACTOR, & OUTPUT TIME DELAYS

The scale factor and preset values are commonly reprogrammed on a daily

basis. As such, single keystroke access has been provided on the front panel.

To change the scale factor, pressthe “3” key. Thedisplay will then show you’re the present scale factor value. The scale factor can be set from -5.9999 to +5.9999.

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.

The newvalue will be entered when the “E”key is pressed. This key mustbeheld down until the displayhas blanked after which the unit will return to the normal display mode.

The internal count value is multipliedby the scale factor value, which changes the displayed value accordingly. This is true for all response modes, Count with Inhibit, Count with UP/DN Control, Two Input Anti-Coincidence and for all Quadrature Counting Modes.

–3–

PROGRAMMING THE PRESETS, SCALE FACTOR, & OUTPUT TIME DELAYS (Cont’d)

The preset level is changed in the same way as the scale factor. Pressingthe “1” key willdisplay the presentvalue of preset 1.

To change the value, merely cycle the digits through as you have done before. The presets can be selected from

-999999 to +999999.

The new value will be entered when the “E” key is pressed. (The display will blank for a short duration of time

and then re-display the count value.)

The Scale Factor value will have a direct effect on the preset being entered. For scale factors greater than one, the preset shouldbe an integer multiple of the scale factor. If it is not, the Gemini will automatically adjust the preset value up or down to force it to be evenly divisible by the scale factor.

A time delay is changed by entering a two-digit function code. The display will then immediately show the present time delay in seconds with a two decimal place accuracy. The time delay valuescan beset from .01 to 599.99 seconds.

To change output1 time delay, enter functioncode 53 and enter the new value by holding down or repeatedly pressing the key below the digit position you wish to change.

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.

As with the other functions, you must press“E” to record the changes. For the data entry modes, if you do not press the “E” key, a time out of 5 seconds occurs, then the display returns to operating mode without any change to the value. The only time any change will occur is when the “E” key is pressed. As in all other modes, the reset button is always active if enabled. Pressing “R” will abort the data entry and reset the instrument.

The new value willbe entered when the “E” key is pressed

and the display will immediately return to the count value.

–4–

FACTORY SETTINGS

Keys Struck Display Description

4,1 41 1 4,3 43 1 4,4 44 1 4,5 45 1 4,6 46 1 5,1 51 1 5,2 52 3 5,3 0000.10

*5,4 54 3 *5,5 0000.10

6,1 61 4 6,6 66 4

3 01.0000 1 000500

*2 001000

When the unit is shipped from the factory, the functions and modes are

programmed as shown above.

*Applies to the Gemini 2000 only.

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 longasbutton remains PUSHED Output 1 terminates at Reset, Normal Output Phase

0.10 second Output 1 time delay. Note that this function will display the actual amount of time delay, and not a mode command. In this case, it displays a 0.10 indicating

0.10 seconds. Output 2 terminates at Reset, Normal Output Phase.

0.10 second Output 2 time delay. Note that this function will display the actual amount of time delay, and not a mode command. In this case, it displays a 0.10 indicating

0.10 seconds. No right-hand dummy zeros

Reset enabled along with scale factor and presets. Scale Factor set to unity Preset 1 value equals 500 Preset 2 value equals 1000

–5–

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 unauthorized personnel can be prevented. However,it may be necessary to allow reset and certain programming functions, such as, preset and scale factor values to be changed in daily operation. The Gemini, through the use of the “Operator

Accessible Functions”Modes, can enablethese functions evenwhen the “PGM. DIS.” terminal is connected to “COMMON”.

The “Operator Accessible Functions” Modes are programmed by a two-digit function code (66), like the other function modes. But in this case, the modes do not take effect until the “PGM. DIS.” terminal is connected to “COMMON”.

(Bear in mind that all function modes of the Gemini are accessible until “PGM. DIS.” is connected to “COMMON”.)

There are four 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 ANDRESET ENABLED - The entirefront

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 - Theentire front panel is disabledwith the exceptions of scale

factor and preset programmability, and manual reset. All functions can be

interrogated.

All of these four basic modes can be modified with the addition of a minus sign. The minus sign disables the manual reset, at the front panel and the remote reset terminal, at the rear of the unit.

There is also a rear panel DIP switch which permits disabling of the front panel manual resetbutton. This isindependent of the rearterminal remote reset,and can be

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.

DIAGNOSTICS, SELF TEST, & “WATCHDOG” TIMER

The security and integrity 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 poweris turned off, on purposeor by accident, all pertinent function settings and measurementsare automatically saved. Then, when power is restored, the function and data are re-instated. This allows you to program a Gemini once and nothave to re-program it until youwish to use it in another mode.

When the function codes and data are saved, computations are made with these values.The result of these computations is stored in the memory to serve as a check against possible error. Then on power up, the same computations are repeated on the stored data. Ifthe results donot agree with thestored results, then a “P” will appear on the left side of the display. If this occurs, refer to the troubleshooting guide for directions.

Another error indicator is the “watchdog” timer. In order to insure proper software functioning, the program constantly monitors itself. If the proper sequence and timingofinternal events doesnotoccur, an “E”will appear onthe left side ofthe display. If this occurs, refer to the troubleshooting guide for instructions.

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 interfere with theaccumulation of counts or controlfunctions. A function code of “6” “+/-” starts thetest. At this time, whatever was displayedwill be replaced by a string of decimal points andthe overflow indicator. Then,the display will show a string of 9’s, then 8’s then 7’s, etc., until a string of 0’s is shown. The self test will then turn offthe overflow indicator and activate the minus(-) sign. After this, the unit showsan interlace pattern of-0, 1, 0, 1,0,1, then -2, 1,2, 1, 2, 1,followed by -2, 3, 2, 3, 2, 3, etc., until -8, 9, 8, 9, 8, 9, is reached. At this time, the outputs can be tested by pressing the “1” and “2” keys.

(The program disablepin must be high inorder to allow activation ofthe output.) Note: During selftest caution should be usedwhen testing the outputs soas not to

cause any undesirable or hazardous conditions in the system.

–6–

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. Various types of sensor outputs can be accommodated by appropriate DIP switch set-up; such as TTL or CMOS logic, current sinking, current sourcing, or dry contact.

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

Channel B is a completely independent count or control input channel. Like Channel A, it can be programmed with DIP switches for a wide variety of logic inputs and is identical to Channel A in this regard.

For a complete detailed description of set-up, see Appendix “A”.

OVERFLOW INDICATION

The Gemini features an overflow indicator (LED) which is located to the left of the sixth digitand 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 before the displayed value wouldoverflow. It should also be noted thatthe use of Right Hand Dummy Zeros or Scale Factors larger than one could cause the Displayed value to overflow before a value of 999,999 (6-digits) is accumulated.

When the capacity of the display is exceeded, the count value will be maintained and willbe valid. Butif the internal countvalue is exceeded, thenthis value may no longer be valid.

–7–

PROGRAMMING INSTRUCTIONS FOR THE COUNTER VERSION OF THE GEMINI

The first part of this section provides detailed description of the function command codes for countingmodes, reset modes, output terminations, etc. Then, using an actual application example, the programming instructions for a counter 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 pertaining to the counter will be discussed in this section.)

CODE 41 - UNIT PERSONALITY

Two basic personalities are available for the Gemini. They are the counter mode and the rate indicator mode.

[41 1] COUNTER- Setting this mode selectstheunit to function as acounter.

This is the basic personality mode and must be programmed before any other modes areset. (This command forces default mode valuesin certain

command codes.)

CODE 43 - INPUTSA&BRESPONSE MODES

The Gemini has six different input response modes. They are: Count with Inhibit; Count with Up/Down Control; Two-Input Anti-Coincidence Add; Two-Input Anti-Coincidence Add/Subtract; Quadrature; and Quadrature X4.

[43 1] COUNT WITH INHIBIT - Input A in this case, serves as the count

input. Input B serves as the inhibit terminal. When Input B is low, count signals appearing at A will be ignored. When Input B is at a high level, negative going (falling) signals appearing at A will be counted.

[43 2] COUNT WITH UP/DOWN CONTROL - When in this mode, count

direction can be controlled by a second input. Input A serves as the count input, and Input B serves as the direction control signal. When B is at a high level, negative going transitions at A will cause the unit to count in the positive direction. When Input B is at a low level, negative going transitions at A will cause thecounter tocountin the negative direction.

[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.

[43 4] TWO (2) INPUT ANTI-COINCIDENCE ADD - This mode functions

in the same manner as the Two Input Add/Subtract mode except both Input A and Input B serve as “ADD” inputs.

[43 5] QUADRATURE COUNTING - Quadrature counting modes are

primarily used in positioning and anti-jitter applications. The reason this mode is used is due to the manner in which two pickups are positioned relative to each other.Input B is a pulsetrain signal shifted 90° awayfrom Input A. These two signals are processed by the Gemini as follows:

Input A serves as the count input, while Input B serves as the quadrature input (B is theinput shifted 90° away from A). Forquadrature with single edge counting, the counter will count in a positive direction when Input A is a negative going edge and Input B is at a low level. The counter will count in a negative direction when Input A is a positive going edge and Input B is at a low level. All transitions on Input A are ignored when B is at a high level. These logic rulesprovide the basis for anti-jitteroperationwhich will prevent false counts from occurring due to back-lash, vibration, chatter, etc.

When two edge counting is used, the quadrature mode works the same as with single edge counting when Input B is low. But when Input B is at a high level, counts atInput A are no longerignored. Instead the logic rulesfor A are complemented, allowing both edges of A to be counted. This doubles the effective resolution of the encoded input.

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

two edge counting, onestep further. In quadrature times 4, both InputAand Input B serve as count or quadrature input, depending on their state. In one instance, Input A will serve as the count input and Input B will serve as the quadrature input. In another instance, Input A will be the quadrature input and Input B will be the count input. This enables each edge, positive and negative going, of each input, A and B, to be counted. This results in a resolution four times greater than in the ordinary quadrature mode.

–8–

CODE 44 - NUMBER OF COUNT EDGES

The Gemini can be programmed for either single edge or two edge (doubling) counting. The number of count edges cannot be set when the count mode is programmed for quadrature X4 operation (the Gemini will ignore any attempt to

enter function command code 44 when set for quadrature X4).

[44 1] SINGLE EDGE COUNTING - The unit 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 - 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 - SCALE MULTIPLIER

There arefour scale multiplier values that are available.They are: 1;0.1; 0.01; and 0.001. They effectively divide the internal count value by 1, 10, 100, and 1000 respectively, to yield the displayed count value. Note: Use of a small scale

multiplier inconjunction with asmall scale factorcould cause theinternal count value to be exceeded before the 6-digit display valueis exceeded. See “Overflow Indication” section for more details.

[45 1] SCALE MULTIPLIER VALUE OF 1 - This value multiplies the

internal count by 1.

[45 2] SCALE MULTIPLIER VALUE OF 0.1 - This value multiplies the

internal count by 0.1. (Effectively divides by 10.)

[45 3] SCALE MULTIPLIER VALUE OF 0.01 - This value multiplies the

internal count by 0.01. (Effectively divides by 100.)

[45 4] SCALE MULTIPLIER VALUE OF 0.001 - This value multiplies the

internal count by 0.001. (Effectively divides by 1000.)

CODE 46 - DECIMAL POINT & LEADING ZERO BLANKING

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

[46 1] 0 [46 2] 0.0 [46 3] 0.0 0 [46 4] 0.000 [46 5] 0.0000 [46 6] 0.00000

[46 -1] 000000 [46 -2] 00000.0 [46 -3] 0000.00 [46 -4] 000.000 [46 -5] 00.0000 [46 -6] 0.00000

LEADING ZERO BLANKING

LEADING ZERO BLANKING INHIBITED

CODE 51 - RESET MODES

The Gemini has six different reset modes. They are: Manual Reset to Zero; Manual Reset to Preset; Automatic Reset to Zero After Output Time Delay; Automatic Reset to Preset after Output Time Delay; Automatic Reset to Zero at the Beginning of the Output Time Delay; and Automatic Reset to Preset at the Beginning of theOutput Time Delay. (Note:For the Gemini 2000,reset to preset modes reset to preset 2 and Output refers to Output 2.) There are also two methods by which manual reset can act on the unit (reset must be enabled). The first is a “maintained” reset action where the unit is held at reset as long as the reset terminal is heldlow or the front panel resetbutton is pressed. The second is a “momentary” reset in which the unit resets when reset is activated and immediately starts countingeventhough the terminal maystill be low or thereset button may still be pressed. (Note: In momentary reset, the display will not

update until reset is released, but internal counting and all other functions are operative.) A “-” sign in front of the code identifier will provide for “momentary” reset, and theabsence ofa “-” sign will give “maintained” reset.

[51 1] MANUAL RESET TO ZERO (RTZ) - Manual reset to zero is

accomplished by pullingremote reset to ground, or if thefront panel reset is enabled, by pressing the frontpanel resetbutton.Reset is “maintained”.

[51 2] MANUAL RESET TO PRESET (RTP) - Manual reset to preset is

accomplished by pulling reset to ground, or if the front panel reset is enabled, by pressing the front panelreset button.Resetis“maintained”.

–9–

CODE 51 - RESET MODES (Cont’d)

[51 3] AUTOMATIC RESET TO ZERO AFTER OUTPUT TIME DELAY -

The counter resets to zero when the output time delay ends. Manual reset is “maintained” and will override automatic reset.

[51 4]AUTOMATIC RESET TOPRESET AFTER OUTPUT TIME DELAY -

The counter resets to the preset value when the output time delay ends. Manual reset is “maintained” and will override automatic reset.

[51 5] AUTOMATIC RESET TO ZERO AT THE BEGINNING OF THE

OUTPUT TIME DELAY - When in this reset mode, the unit will automatically reset to zero atthe beginningof the output time delay (when the preset point is reached).For the Gemini 2000, the output1 and output 2 time delays must be shorter than the time required for the counter to count to the preset 2 value. Otherwise, the output(s) will appear to be latched on. Manual reset is “maintained” and will override automatic reset.

[51 6] AUTOMATIC RESET TO PRESET AT THE BEGINNING OF THE

OUTPUT TIME DELAY - In this reset mode, the unit will automatically reset to preset at the beginning of the output time delay (when zero is reached). For the Gemini 2000, the output 1 and output 2 time delay must be shorter than the time required for the counter to count to zero. Otherwise, the outputs will appear to be latched on. Manual reset is “maintained” and will override automatic reset.

[51 -1] [51 -2] [51 -3] These modes are the same as above with the exception [51 -4] that Reset is set for “momentary” operation. [51 -5] [51 -6]

CODE 52 - OUTPUT 1 TERMINATION MODES

The Gemini has six Output Termination Modes. They are: Terminate at Output 2 Start; Terminate at Output 2 End; Terminate at Manual Reset; Terminate at Manual Reset End; Terminate After Time Delay; and Boundary.

A Reverse Phase Option is available on the Gemini. This refers to complementing the logic state of the output. With normal phase operation, when the count reaches preset 1 the output will turn on. The reset condition of the output is output off. In reverse phase operation, the output turns off when the

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 beturned off. This isdone to help preventa hazardous situation from occurring. If other than boundary or time delay operation is selected, the unit should be reset upon power up.

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

Output 2 starts. (Gemini 2000 only) [52 2] TERMINATE AT OUTPUT 2 END - Output 1 will terminate when

Output 2 terminates. (Gemini 2000 only) [52 3] TERMINATE AT MANUAL RESET - In this mode, output 1, once

activated, does notdeactivate until the momenta reset occurs. The resetcan 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. [52 4] TERMINATE AT MANUAL RESET END - This mode is like the

preceding output mode, except output 1 deactivates when the reset ends. The

output is set for normal phase operation. [52 5] TERMINATE AFTER OUTPUT 1 TIME DELAY - Once output 1 has

been activated, it will deactivate after the predetermined length of output 1

time delay has expired. Manual reset, by either the front panel button or the

reset terminal, will override the output 1 time delay and reset the output. The

output is set for normal phase operation. [52 6] BOUNDARY MODE - This mode can be used when the unit is

functioning as a counter, but is more applicable to the rate indicator mode.

When in boundary mode, the preset 1 value serves as the boundary point.

When the count is less than the preset, the output is not activated (normal

phase). When the count is greater than or equal to the preset, the output is

activated. Ifthe count value were to drop belowpreset, the outputwould again

deactivate. For negative preset points, the output is not activated when the

count value is more positive than the preset value. When the count is more

negative than or equal to the preset, the output is activated. If the count

becomes more positive than the preset, the output again deactivates. Upon

power up, the output will “remember” its power down boundary condition

and go to that state. The output is set for normal phase operation.

–10–

[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 - OUTPUT 1 TIME DELAY

The Gemini hasthe capability of varying theoutput time delay from 0.01second to 599.99 seconds. When the code is entered, instead of a single mode identifier digit beingdisplayed, six digits will beshown. Refer tothe “Programming Preset, Scale Factor, and Output Time Delay” section for more details about entering. Output time delay will be terminated if the unit is manually reset.

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 not enter the 0, but will revert back to displaying the previous time delay.

CODE 54 - OUTPUT 2 TERMINATION MODES (GEMINI 2000 Only)

The Gemini 2000 hassixOutput 2 Termination Modes. They are:Terminateat Output 1 Start; Terminate at Output 1 End; Terminate at Manual Reset; Terminate at Manual Reset End; 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. With normal phase operation,when the count reaches preset 2, output 2 will turn on. The reset condition of the output is output off.In reverse phaseoperation,the output turnsoff when thepresetis reached. The reset condition of the outputis outputon. (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.

[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 notdeactivate until the momenta reset occurs. The resetcan be from the front panelbutton or from the remote reset terminal,at the rear of the unit. The output is set for normal phase operation.

[54 4] TERMINATE AT MANUAL RESET END - This mode is like the

preceding output mode, except output 2 deactivates when the reset ends. The output is set for normal phase operation.

[54 5] TERMINATE AFTER OUTPUT 2 TIME DELAY - Once output 2 has

been activated, it will deactivate after the predetermined length of output 2 time delay has expired. Manual reset, by either the front panel button or the reset terminal, will override the output 2 time delay and reset the output. The output is set for normal phase operation.

[54 6] BOUNDARY MODE - This mode can be used when the unit is

functioning as a counter, but is more applicable to the rate indicator mode. When in boundary mode, the preset 2 value serves as the boundary point. When the count is less than the preset, the output is not activated (normal phase). When the count is greater than or equal to the preset, the output is activated. Ifthe count value were to drop belowpreset, the outputwould again deactivate. For negative preset points, the output is not activated when the count value is more positive than the preset value. When the count is more negative than or equal to the preset, the output is activated. If the count becomes more positive than the preset, the output again deactivates. Upon power up, the output will “remember” its power down boundary condition and go to that state. The output is set for normal phase operation.

[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]

–11–

CODE 55 - OUTPUT 2 TIME DELAY (GEMINI 2000 Only)

The Gemini 2000 has the capability of varying the output time delay from 0.01 second to 599.99 seconds. When the code is entered, instead of a single mode identifier digitbeing displayed, sixdigits will beshown. Refer to the “Programming Preset, Scale Factor, and Output Time Delay” section for more details about entering. Output time delay will be terminated if the unit is manually reset.

Note: A time delayvalue of zero cannot be programmed into theGemini 2000.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 revert back to displaying the previous time delay.

CODE 61 - RIGHT HAND DUMMY ZEROS

These zerosare used toeffectively move significantdigits to theleft. Up tothree non-functional zeros canbe used. Therefore, a normalcountof 1 could be shownas a 10, 100, or1000 without setting or changing anyother parameter of the system.

Note: Use ofdummy zeros or scale factorvaluesgreater than one could causethe

displayed value to overflow before a value of 999,999 (6-digits) is

accumulated. See “Overflow Indication” section for more details.

[61 1] 1 RIGHT HAND DUMMY ZERO - One is displayed. [61 2] 2 RIGHT HAND DUMMY ZEROS - Two are displayed. [61 3] 3 RIGHT HAND DUMMY ZEROS - Three are displayed. [61 4] NO RIGHT HAND DUMMY ZEROS - None are displayed.

CODE 66 - “OPERATOR ACCESSIBLE FUNCTIONS” MODES

(PGM. DIS. Connected to “COMMON”)

The Gemini has four basic levels of “Operator Accessible Functions”. However, each of these levels canbe modified to enable or disable manual reset. When the “PGM. DIS.” (program disable) terminal is connected to “COMMON”, access to all functions is disabled except for those listed below which will remain enabled. All of the function codes and parameters can be interrogated regardless of the“Operator AccessibleFunctions” mode selected.

A “-”sign in front of themode identifier will disable resetand the absence of a

“-” sign will enable the reset terminal and front panel reset button. (Note: Front panel reset can be independently “Disabled” by using the disable

reset DIP switch.)

[66 1] NO FUNCTIONSENABLED 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 ANDRESET 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.

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

PRESET VALUES

Whenever the count value equals the preset value, an output action will occur. (This action depends on the previously programmed modes). The Preset Value may vary from -999,999 to999,999. Refer to “Programming ThePresets, Scale Factors, And Timed Output Values” section for instructions on entering the Preset Value.

The Scale Factor valuewillhave a direct effect on thepreset being entered. 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 automatically adjust 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 2000 ONLY)

SCALE FACTOR

“3” SCALE FACTOR - The internal count value is multiplied by the scale factor value, which changes the displayed value accordingly. This is true for all response modes, Count with Inhibit, Count with UP/DN Control, Two Input Anti-Coincidence and for all Quadrature Counting Modes. 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.). The scale factor value may range from -5.9999 to 5.9999. (Refer to “Programming The Presets, Scale Factor & Output Time Delays” section for entering instructions.)

–12–

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 permeasuring 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. 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 to be exceeded before the 6-digit display

value is exceeded. See “Overflow Indication” section for more details.

–13–

DUAL PRESET COUNTING & PROGRAMMING APPLICATION EXAMPLE

A typical industrialapplicationfor Gemini 2000 will requirebotha slow down output and a finalstop output. The Gemini can easily beprogrammed to solve this requirement. For instance, let’s look at a textile web process that requires a dual output asthe web progresses to the proper length. A typical lengthof 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. In this case, it would be best to set the unit up as Manual Reset to Preset 2. Preset 2 would be set at 10,000, and Preset 1 would be set for 500. The counter would count down to 500, and output 1 would activate and cause the process to slow down until 0 is reached at which point Output 2 would activate and latch for final stop. The advantage of using manual Reset to Preset 2 is that when changing the total length it is only necessary to change Preset2 (length). Preset 1 (slow down) would remain the same, assuming the same amount of slow down is required.

The accompanying drawing shows an LMPC sensing a 60 tooth gear which is attached to a 2.5 ft. circumference drum. Since the unit of measure is a foot, the first step is to find the number of pulses per foot that will be used. The following formula is used.

Pulses/ft. = 60 pulses/rev.

2.5 ft./rev.

Since the desired readout is in feet, and there are 24 pulses per foot, it is necessary to scale the count. To determine the multiplier that is needed, the formula below is used.

“desired reading”=1=0.0416667

“# of pulses” 24

To get the maximum amount of decimal point accuracy a scale multiplier of

0.01 (divide by 100) is used which would give us a scale factor (rounded off) of

4.1667. If we used the multiplieras the scale factor,and used ascale multiplier of 1, the scale factor would round off to 0.0417, in which case 2 decimal places of accuracy would be lost.

= 24 pulses/ft.

–14–

HARDWARE SET-UP

The application drawing shows how the hardware for this system is to be connected. The Red, Black, and White wires of the LMPC are connected to the DC OUT, COMM., and INPUT A terminals respectively. The shield of the LMPC cable is also connected to COMM. A Remote reset button is connected between the RST.and COMM. terminals. After theprogramming is completed, a jumper is connected between PGM. DIS. and COMM. terminals of the Gemini

2000. This terminal, in conjunction with the “Operator Accessible Functions” mode, will prevent accidental changes in the units operating modes. The Normally Open contact of Relay 1 is connected to the slow down actuator, and the Normally Open contact of Relay 2 is connected to the motor control.

DIP switch1 is set tothe LOGIC position.This allows Input Ato function asthe count input. Switch position 2 is set to SNK. (current sinking), which provides an internal pull-upresistor to 12 VDC.Position 3 is setto HI FRQ. becauseof the high count speeds involved. Position 4 is set to HI BIAS for higher noise immunity. Since theGemini 2000 willbe counting down, Input B will beused as thedirection input which will be fixed. To count down, Input B must be held low. To do this, switch position5 can beset in theSRC. position whichconnects a 3.9K pull-down resistor at InputB to COMM. The positionsofswitches 6 and 7 areset, as shown, to provide highest noise immunity. Switch position 8 is set to RST. EN. to allow the front panel reset of the Gemini 2000 to operate.

STEP BY STEP PROGRAMMING OF THE GEMINI 2000

Refer to the programming section for instructions on programming function codes and entering Scale factor and Presets.

STEP 1 - Select function code 41 (Unit Personality). Select and enter an

identifier of 1 if it isn’t already. This sets unit personality to a counter. STEP 2 - Enter function code 43 (InputA&BResponse Modes), and enter a

mode identifier of 2 (A = CNT, B = UP/DN). STEP 3 - Enter function code 44 (Number of Count Edges), and enter a 1 for

single edge counting. STEP 4 - Enter function code 45 (Scale Multiplier Values), and enter a mode

identifier of 3 for a scale multiplier of 0.01. STEP 5- Enter function code 46 (Decimal Point & Leading Zero Blanking), and

enter a mode identifierof 1for no decimal points with Leading ZeroBlanking.

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 activatedshould remain so until the unitis reset for start up.

STEP 8 -Enter function code 54(Output 2 Termination Mode),and enter a mode

identifier of-3 (Terminate at start ofManual Reset, reverse phase operation). This mode was selected so that when the system is powered up, the relay would be in the open condition which is motor drive off. To start the process, the Reset button is pushed which would close the Output 2 Relay (turn on motor drive) and would stay closed until 0 is reached, at which time it would open (turn motor drive off).

STEP 9 - Enter function code 61 (Right Hand Dummy Zeros), and enter a mode

identifier of 4 for no Right Hand Dummy zeros.

STEP 10- Press 1and then enterthe desired slowdown value (500is used inthis

application).

STEP 11 -Press 2 and enter the totallength of material to beprocessed (10,000 feet). STEP 12 - Press 3 and enter a scale factor value of 4.1667. STEP 13 - Enter code 66 (Operator Accessible Functions Modes) and enter a

mode identifier of 2 (Presets and Reset Enabled). When the “PGM. DIS.” terminal is connected to “COMM.”, the only changes that will bepossible are resetting the unit and changing the presets.

–15–

PROGRAMMING INSTRUCTIONS FOR THE RATE INDICATOR VERSION OF THE GEMINI

The first part of this section provides detailed descriptions of the function command codes for scale multiplier, leading zero blanking, output terminations, etc. Then,using an actual applicationexample, the programminginstructions for a rate indicator will be “walked through” togive 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 Appendix “D”, lists all codes. (Only commands

and modes pertaining to the rate indicator will be discussed in this section).

CODE 41 - UNIT PERSONALITY

Two basic personalities are available for the Gemini. They are the counter mode and the rate indicator mode.

[41 2] RATE INDICATOR - Setting this mode selects the unit to function as a

rate indicator. This is the basic personality mode and must be programmed

before any other modes are set. (This command forces default mode values in

certain command codes.)

CODE 44 - NUMBER OF COUNT EDGES

The Gemini can be programmed for either single edge or two edge (doubling) counting.

[44 1] SINGLE EDGE COUNTING - The unit counts on the negative going

(falling) edge of the count input signal. [44 2] TWOEDGECOUNTING - This mode is usedwhen 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. This

effectively doubles the resolution

of the input signal.

CODE 45 - SCALE MULTIPLIER

[45 1] SCALEMULTIPLIER VALUE OF 1 -This value multiplies theinternal

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.)

CODE 46 - DECIMAL POINT & 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 - RESET MODES (Manual Reset to Zero)

In the majority of rate indicator applications, the settingof function code 51 is not relevant to the desired operation of the unit, and thus need not be programmed. TheGemini is designed to automatically update atthe end ofevery sample time cycle, which will provide a continuous rate indication reading, as is

–16–

the case withall standard rate indicators.In order toensure this type ofoperation, it is important that the reset Disable/Enable switch be disabled to preclude any unwanted re-start of the sample time cycle.

Certain special application requirements may exist for the sample time cycle to commence at a specific time. In these applications, the remote reset terminal or the front panel reset button (if the Disable/Enable switch is set to the enable position), may be usedto activate the following tworeset modes, thus starting thesample time.

[51 1] MANUAL RESET TO ZERO (RTZ) - Manual reset to zero is

accomplished by pulling remote reset to ground or by pressing the front panel

reset button. In this mode the sample time is initiated immediately upon

release of the reset button. [51 -1] MANUAL RESET TO ZERO (RTZ) - Same as [51 1] except that the

sample time is initiated immediately upon pressing the reset button.

CODE 52 - OUTPUT 1 TERMINATION MODES

The Geminihas two standard Output 1 Termination Modes whenoperating as a rate indicator. They are: Terminate After Time Delay and Boundary.

A reverse phase option is available on the Gemini. This refers to complementing the logicstate of the output.For normal phase operationthe reset condition of the output is output off. For reverse phase operation 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.

[52 5] TERMINATE AFTER OUTPUT 1 TIMEDELAY - In this mode, output 1

activates at the end of eachsample time in which the rate is lower than Preset 1

Once the output has been activated, it will deactivate after the predetermined

length of output 1 time delay has expired. If the output 1 time delay is longer

than thesample time, the output time delay will continually be restarted without

timing out until the rate exceeds the Preset 1 value. Manual reset, by either the

front panel button or the reset terminal, will override the output time delay and

reset the output. The output is set for normal phase operation. [52 6] BOUNDARY MODE - When in the boundary mode, the preset 1 value

serves as the boundary point. When the rate value is more negative than the

preset, theoutput is not activated. When the rate value is more positivethan or

equal to the preset, the output activates. If the rate value were to drop below

preset, the outputwould again deactivate. For negative presetpoints(Negative

Scale Factor), the output is not activated when the rate value is more positive than thepreset value. When the rate value is more negative thanor equal tothe preset, theoutput is activated.If the ratevalue becomes more positive than the preset, the output again deactivates. The output is set for normal phase.

In addition,when functioning as a rate indicator, the Geminialso has two special

use function modes, Terminate at Manual Reset and Terminate at Manual Reset End. These modes are infrequently used. However, they may be useful when a requirement exists to latch and manually release the output.

[52 3] TERMINATE AT MANUAL RESET - In this mode, Output 1 activates

when the rate exceeds the Preset 1 value. Once activated, the output 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.

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

preceding output mode,except the output deactivates whenthereset ends. The output is set for normal phase operation.

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

CODE 53 - OUTPUT 1 TIME DELAY

The Gemini hasthe capability of varying theoutput time delay from 0.01second

to 599.99 seconds. When the code is entered, instead of a single mode identifier

digit beingdisplayed, six digits will beshown. Refer tothe “Programming Preset, Scale Factor, and Output Time Delay” section for more details about entering. Output time delay will be terminated if the unit is manually reset.

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 not enter the 0, but will revert back to displaying the previous time delay.

–17–

CODE 54 - OUTPUT 2 TERMINATION MODES (Gemini 2000 Only)

The Gemini 2000 has two standard Output 2 Termination Modes when operating as a rateindicator. Theyare 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. (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.

[54 5] TERMINATEAFTEROUTPUT 2 TIME DELAY -In this mode, output 2

activates atthe end of eachsample time in whichthe rate is higherthan Preset 2

Once outputhas been activated,it will deactivateafter the predeterminedlength

of output 2 time delay has expired. If the output 2 time delay is longer than the

sample time, the output time delay will continually be restarted without timing

out until the rate is lower than Preset 2 value. Manual reset, by either the front

panel button or the reset terminal, will override the output time delay and reset

the output. The output is set for normal phase operation. [54 6] BOUNDARY MODE - When in the boundary mode, the preset 2 value

serves asthe boundary point.Whenthe rate value ismorenegative than the preset,

the output is not activated. When the rate value is more positive than or equal to

the preset, the output is activated. If the rate value were to drop below preset, the

output would again deactivate. For negative preset points (Negative 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 operation.

In addition, when functioning as a rate indicator, the Gemini 2000 also has two

special use function modes, Terminate at Manual Reset and Terminate at

Manual Reset End. These modes areinfrequently used. However, theymay be

useful when a requirement exists to latch and manually release the output.

[54 3] TERMINATE AT MANUAL RESET - In this mode, Output 2 activates

when the rate exceeds the Preset 2 value. Once activated the output 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.

[54 4] TERMINATE AT MANUAL RESET END - This mode is like the

preceding output mode,except the output deactivates whenthereset ends. The output is set for normal phase operation.

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

CODE 55 - OUTPUT 2 TIME DELAY (Gemini 2000 Only)

Note: A time delayvalue of zero cannot be programmed into theGemini 2000.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 revert back to displaying the previous time delay.

CODE 61 - RIGHT HAND DUMMY ZEROS

Note: Use ofdummy zeros or scale factorvaluesgreater than one could causethe

displayed value to overflow before a value of 999,999 (6-digits) is

accumulated. See “Overflow Indication” section for more details.

–18–

CODE 63 - SAMPLE TIME

The Gemini offers six different lengths of sample times. They are 1 second; 2 seconds; 5seconds; 10 seconds; 20seconds; 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. (For an explanation of how to determine the proper sample time, refer to Appendix “E”).

[63 1] SAMPLE TIME OF 1 SECOND [63 2] SAMPLE TIME OF 2 SECONDS [63 3] SAMPLE TIME OF 5 SECONDS [63 4] SAMPLE TIME OF 10 SECONDS [63 5] SAMPLE TIME OF 20 SECONDS [63 6] SAMPLE TIME OF 50 SECONDS

CODE 66 - “OPERATOR ACCESSIBLE FUNCTIONS” MODES

(PGM. DIS. Connected to “COMMON”)

The Gemini has four basic levels of “Operator Accessible Functions”. However 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 functions is disabled except for those listed below which will remain enabled. All of the function codes and parameters can be interrogated, regardless of the“Operator AccessibleFunctions” mode selected.

A “-”sign in front of themode identifier will disable resetand the absence of a

“-” sign will enable the reset terminal and front panel reset button. (Note: Front panel reset can be independently “Disabled”

reset DIP switch.)

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

reset is enabled, but none ofthe programmingfunctionscan 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, 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.

by using the disable

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

PRESET VALUES

“1” - PRESET 1 VALUE

“2” - PRESET 2 VALUE (GEMINI 2000 ONLY)

SCALE FACTOR

“3” SCALE FACTOR - The internal count value is multiplied by the scale factor value,which changes the displayed value accordingly. 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.). The scale factor value may range from -5.9999 to 5.9999. (Refer to “Programming The Presets, Scale Factor & Output Time Delays” section for entering instructions.)

–19–

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 thatis attached on the drive roll. In this case, the RPG is delivering 120 pulses/rev. and the circumference of the rollis 6.35 ft. By substituting in our formulas as shown in Appendix “E”, the correct parameters are determined.

FORMULA [A]

FORMULA [B]

SCALE FACTOR

By programming a 1.5875 Scale Factor and a 2-second sample time, the Gemini 2000 will display the FPM of the roll every 2 seconds. If added resolution is desired, the number of count edges could be changed to 2, and the scale factor would become 0.7938.

The drive mechanism of the roll will react to a contact closure to increase or decrease speed at a set rate for the duration of the closure. The 2-second sample time with a 0.5 second closure (Time delay) at the beginning of each sample time, will allow the web process to remain within the lower and upper tolerances. In this application, the lower speed limit is 500 FPM and the upper limit is 700 FPM. When time delay output termination modes are used in the Gemini 2000, Output 1 activates when the rate is lower than Preset 1 and Output 2 activates when the rate is higher than Preset 2. With this in mind, Output 1 is connected to the speed increase drive and set to the lower limit andOutput 2 is set tothe upper limit of thespeed range. When the rate drops below 500 FPM for the 2-second sample time, Output 1 will activate for0.5 seconds. Conversely, when the rate exceeds700 FPM forthe 2-second sample time, Output 2 will activate for 0.5 seconds.

PPS

RPM x PPR=1 x 120=2 PPS

60 sec. 60

DESIRED READING=6.35=1.5875

PPS x SAMPLE TIME 2x2

–20–

HARDWARE SET-UP

The application drawing shows how the hardware for this system is to be connected. The Red (supply), Black (Common), and White (signal) leads of the RPG Cable are connected to the “DC OUT”, “COMM.”, and “INPUT A” terminals respectively. The shield of the cable is connected to “COMM.”. The normally open contact of Relay 1 is connected to the “Speed Increase Control” and the normally open contact of Relay 2 is connected to the “Speed Reduction Control”.A“Start” button isused to start upthe system and getit “up to speed”, at which point the Gemini 2000 can take over and control the speed. After programming is completed, a jumper is placed between the “COMM.” and “PGM. DIS.” terminals of the unit. This terminal, working in conjunction with the “Operator Accessible Functions” mode, will prevent accidental changes in the unit’s operating modes.

The Input DIP Switch position 1 is set to the LOGIC position since an RPG is being utilized. Position 2 is set to “SNK.”, which provides an internal pull-up resistor to +12 VDC. (The RPGB has an open collector sinking output.) Position 3 is set to“HI FRQ.” since the input rate will be over 100 cps. Position 4 is set to “HI BIAS” to provide higher noise immunity. Because Input B is not used, the settings of Positions 5-7 are all selected as shown to provide maximum noise immunity. Position 8 is set to “DIS.RST.” to disable the frontpanel reset button. For more detailed descriptions of the Input switch set-up, see Appendix “A”.

STEP BY STEP PROGRAMMING OF THE GEMINI 2000

The steps for programming the Gemini should be followed in this order each time a change is made ina basic parameter ofthe system. (The preset value, scale

factor value and output time delay value can be changed at any time or in any sequence, provided the unit is already operating in a valid mode, and an “Operator Accessible Functions” mode is not preventing this change.)

Refer to the programming section, for instructions in programming function codes and entering Scale Factor and Preset Values.

STEP 1 - Enter code 41 (Unit Personality), and a mode identifier of 2 for a rate

indicator unit personality. STEP 2 - Enter code 44 (Number of Count Edges), and enter 1 for single edge

counting.

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 5for time delay

operation.

STEP 6 - Enter code 53 (Output 1 Time Delay) and enter a time delay value of

0000.50.

STEP 7 - Enter code 54 (Output 2 Termination Modes) and enter a mode

identifier of 5 for time delay operation.

STEP 8 - Enter code 55 (Output 2 Time Delay) and enter a time delay value of

0000.50.

STEP 9 - Enter code 61 (Right-Hand Dummy Zeros) and enter an identifier of 4

for no right-hand dummy zeros.

STEP 10 - Enter code 63 (Sample Time) and enter a mode identifier of 2 for a 2

second sample time.

STEP 11 -Press “1”. Enter the lowerspeed limit for Preset 1which is 000500 for

this application.

STEP 12 - Press “2”. Enter the upper speed limit for Preset 2, which is 000700

for this application.

STEP 13 - Press“3”. Enterthe Scale factor for this application whichis 1.5875. STEP 14 -Enter code 66 (“Operator AccessibleFunctions”mode) and enter a -1

for all Operator Functions disabled. For this application the Scale Factor and speed limits are fixed and do not require changing. Also there is no need to reset the Sample time so Reset is locked out. (Note: After this code is

programmed, the “PGM. DIS.” terminal is connected to “COMM.” to prevent any accidental changes.)

–21–

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 devicesthat can be connectedwith the Gemini 2000are: a printer,terminal, programmable controller, or host computer. For devices that use RS232, a GCM232 SerialConverter Module is available to convert the20 mA CurrentLoop signals to RS232 and vice-versa.

There are two loops that must be established. One for sending commands to the Gemini 2000 and one for receiving the data values from the Gemini 2000. Up to sixteen Geminis or other RLC units with 20 mA serial communication capability, can be connectedtogether in the “loop” ifa24 V external current sourceis utilized. A maximum of seven units can be installed in the loop if the Gemini’s 20 mA current source is used. The units are assigned addresses by setting the Serial DIP Switches on each unit. The applications can be as simple as attaching a printer to obtain hardcopy of the displayinformation or as involvedas using a hostcomputer to automatically set up Presets and Scale Factors on a number of Geminis.

With the Communications Option,the followingfunctions can be performed:

1. Interrogation of the Count Value, Presets, and Scale Factor.

2. Changing of the Presets and Scale Factor.

3. Resetting of the Count Value and Outputs.

4. Automatic print-out whenusing aprinter and the “Print Request” Terminal.

COMMUNICATION FORMAT

Data is sentby switching off and on thecurrentin the 20 mA currentloop.Data is receivedby monitoring theswitching action andinterpreting the codesthat are transmitted. In order for data to be interpreted correctly, there must be identical formats and Baud Rates.

The format that the Gemini 2000 will acceptis: 1 start bit, 7 data bits, 1 odd parity bit, and 1stop bit. The Baud Ratesthat are available are: 300,600, 1200 and 2400.

The selection of the Baud Rate is done by setting DIP switches. Refer to the

“Current Loop Installation” section, for set-up instructions.

FIG. 1: DATA FORMAT-10 BIT FRAME [300, 600, 1200, 2400 Baud]

SENDING COMMANDS & DATA TO THE GEMINI 2000

When sending commands to the Gemini 2000, a command string must be constructed. The command string may consist of command codes, value identifiers, and numerical data. Following is a list of commands and value identifiers that are used when communicating with the Gemini 2000.

COMMAND DESCRIPTION

N (4EH) Address command; followed by a one or 2 digit unit address

P (50H) Transmit per Print Options command. R (52H) Reset command T (54H) Transmit Value command; followed by a value identifier

V (56H) Change Value command; followed by a value identifier (A, B,

X (58H) Transmit and reset count command.

number 1-15 and one of the following commands.

(A-D); operates on count value, Presets and Scale Factor.

D); operates on Scale Factor and Presets.

VALUE

IDENTIFIER

A (41H) Preset 1 (PS1) B (42H) Preset 2 (PS2) C (43H) Count Value (CNT) D (44H) Scale Factor (SCF)

DESCRIPTION MNEMONIC

–22–

The command string is constructed by using the above commands and value identifiers, along with the data values that are required. Data values may or may not contain the decimal point if a decimal point is programmed into the Gemini

2000. The Gemini 2000 will accept the decimal points, however, it does not interpret them in any way. Leading zeros can be eliminated, however, all trailing zeros must be present. For example, if a Scale Factor of 1.0000 is to be sent, the data value can be transmitted as 1.0000 or 10000. If a “1” is transmitted, the Scale Factor will be changed to 0.0001.

The Addresscommand is used to allow a command to be directed to a specific unit in the Serial Communications Loop. Whenever the unit address is zero, transmission of the Address command is not required. This is done for applications which do not require more than one Gemini. For applications that require several units, it is recommended that each unit in the loop be given a separate address. If they are given the same address, a command such as the Transmit Value Command, will cause all the units to respond at the same time, resulting in erroneous data.

The commandstring is constructed ina specific logicalsequence. The Gemini 2000 willnot accept command strings that do not followthis sequence. Onlyone operation can be performed per command string. Below is the procedure to be used when constructing a command string.

1. If the Gemini 2000, to which the command is to be sent, is assigned an

address other than zero, the first two or three characters of the command

string must consist of theAddress Command (N) and the address number of

the unit (1-15).

2. The next character(s) in the command string is the actual command that the

Gemini 2000 is to perform and the value identifier if it pertains to the

command. (A command such as the Transmit per Print Options, “P”,

command does not require a Value Identifier.)

3. If the change command is being used, the next characters in the command

string are the numerical data value.

4. The last character in the command string is the command terminator (*). This

character must be sent in order to tell the Geminis that the command string is

complete, so that they can begin processing the command.

Below are some typical examples of properly constructed command strings. (EX. 1) Change Preset 1 on the Gemini 2000 with an address of 2 to 00123.4.

COMMAND STRING: N2VA1234*

(EX. 2) Have the Gemini 2000, with an address of 13, transmit the Count value.

COMMAND STRING: N13TC*

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.

When writing application programs in Basic, the transmission of spaces or carriage return andline feed should beinhibited by using the semicolondelimiter with the PRINT statement. The Gemini 2000 will not accept a carriage return or line feed as valid characters.

When a “Change Value” command issent to the Gemini2000, a short amount of time is required for the unit to process the data. This time increases with the count rate. During this time, only one additional command may be sent to the Gemini 2000. This may be done 80 msec after the transmission of the “Change Value” command. After the second commandhas been transmitted, the unit will ignore any further commands until 10 msec after both the “Change Value” and second command have been processed. It is recommended that a “Transmit Value” command follow a “Change Value” command. If this is done, the reception of the data can provide a timing reference for sending another command and will insure that the change has occurred.

The timing diagrams show the timing considerations that need to be made.

FIG. 2: TIMING FOR SENDING COMMANDS

(**) This is the time that it takes the Gemini 2000 to process the preset.

It varies with the Count Rate and Scale Factor Value.

FIG. 3: TRANSMIT COUNT & RESET COMMAND TIMING

–23–

RECEIVING DATA FROM THE GEMINI 2000

Data is transmitted from the Gemini 2000 when a “Transmit Value” or “Transmit per Print Options” command is sent to the unit, or when the “PRINT REQ.” terminal is activated. The Gemini 2000 can transmit 4 values: Count

value, Presets1&2,andScale Factor. A list of the abbreviations used when the Gemini 2000 transmits the values are shown below.

CNT - Count Value

PS1 - Preset 1

PS2 - Preset 2

SCF - Scale Factor

A typical transmission, with the “PR.ID” (Print ID) switch in the upposition, is shown below.

The first two digitstransmitted are the unit addressfollowed by two blank spaces. If the unit address is 0, the first locations will be left blank. The next three letters are the abbreviation for the mnemonic value followed by one blank space. The actual values are transmitted last. Negative values are indicated by a “-” sign. For positive values, the “+” sign is not transmitted. Overflowed count values are shown by an asterisk preceding the most significantdigit of the value. The decimal point position will “float” within the data field depending on the actual value it represents.

For peripheral control purposes, a single line transmission will have a <CR> attached to the end of the above string. For a “T” command or each line of a block transmission, only the above character string is sent. For the last line of a block transmission, a <SP><CR> <LF> is attached tothe end of the abovecharacter string.

An example of a typical serial transmission:

3 CNT -1234.56 < CR> < LF>

If the “Print Request” terminal initiates the transmission, a 400 msec delay is inserted before the transmission to keep multiple transmissions from overrunning the printer.

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 printersmay not work, since theprinter delay is not transmitted.

PRINT OPTIONS

The various Print Optionsare used mainly in conjunction with aprinter and the Print Request Terminal. They provide a choice of Gemini 2000 data values to be printed when either the Print Request Terminal is activated or the “Transmit per Print Options” (P) command is sent to the Gemini 2000. The various Print Options available are:

1. Print Count Value Only

2. Print Count Value & Presets

3. Print Count Value & Scale Factor

4. Print Count, Presets, & Scale Factor

A typical printoutis shown below. The PrintOptions are selected by settingS4 and S5 on the Serial DIP Switch. See “Serial DIP Switch Set-up” section for the various switch settings.

1 CNT 000054 1 PS1 000100 1 PS2 000200 1 SCF 01.0000

The Transmit Count and Reset action of the (X) command is available for use with thePrint Options. This option is selected by setting the TRST switch (Serial switch position 6) in the down position. This capability is useful in a totalizing application wherea “shift total” is desired without shuttingdown the machineto take the reading and reset the unit.

FIG. 4: TRANSMIT COUNT & RESET (TRST) PRINT OPTION TIMING

–24–

CURRENT LOOP INSTALLATION

WIRING CONNECTIONS

When wiring the 20 mA current loop, remove the 7-position terminal block (TBD), locatedon the rightside of thetop board. Referto 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. This unit meets the EMC specifications using Alpha #2404 cable or equivalent. There are higher grades of shielded cable, such as, four conductor twisted pair, that offer an even higher degree of noise immunity.

TERMINAL DESCRIPTIONS FOR TERMINAL BLOCK TBD

1. -20 mA SRC (COMMON) - Common for 20 mA SRC & Print Request

terminal.

2. PRINT REQUEST - The Print Request Terminal is connected to common to

request the Gemini 2000 to transmit according to the Print Options mode that

has been selected. (Minimum Activation time = 25 msec.)

3. +20 mASRC - The 20 mASRCterminal provides the source currentforone of

the loops.

4. SO- (Serial Out-)

5. SO+ (Serial Out+)

The Gemini 2000 transmits the requested data on these terminals (SO- &

SO+). They are connected in series to the receive input of the device to be

connected.

6. SI- (Serial In-)

7. SI+ (Serial In+)

The Gemini 2000receives commands on these terminals(SI-& SI+). They are

connected in series with the transmit or output terminals of the device to be

connected.

Note: The serial input terminals must be held in the mark condition

(current on) in order for the Gemini 2000 to respond to a Print Request terminal activation.

–25–

CURRENT LOOP INSTALLATION (Cont’d)

SERIAL DIP SWITCH SET-UP

The SerialDIP switches areaccessible through the side of the Gemini 2000. A list of the DIP switch positions and their functions are shown in Figure 5.

BR0 & BR1, BAUD RATE - Set-up is shown in Figure 5, below. When

changing the Baud Rate, the unit should be powered-down and then powered

back up again.The unit will only recognize abaudrate change upon power-up,

after activating the “Print Request” terminal or after a few characters have

been sent at the new baud rate (If the two previous conditions have not

occurred, the Geminiwill see the charactersas erroneous and itwill check the

baud rate and set itself to operate at the new rate).

PR.ID - PRINT ID. - When this switch is in the up position, the Gemini 2000

will print the unit address, data value ID and the data value when a

transmission is requested. The unit will also insert a 400 msec delay between

transmissions when the “P” command or Print Requestterminal is used. This

switch position is generally used when the unit is connected with a printer.

FIG. 5: DIP SWITCH SET-UP

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, willnot be inserted.This switch positionusage is intendedfor 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.

PC0 & PC1, PRINT OPTIONS - Used to control which values are transmitted

when the Print Request terminal is activated or when the Transmit per Print Options command “P” is sent to the Gemini 2000.

TRST, TRANSMIT CNT & RESET - Used in conjunction with Print Options.

When this switch isin the downposition, the unit will transmitand reset the count when the “PRINT.REQ.” terminal is activated orthe (P) command isreceived.

AD0, AD1, AD2 & AD3, UNIT ADDRESS - These switches are used to give

each unit aseparate address when morethan one unit isconnected in the Loop. See Figure 5, for Switch Set-up.

When connecting a printer or any device in whichthe Gemini 2000’s Serial Inputs (SI+, SI-) are not used, they must still be connected to a 20 mA source and be in the Mark condition (Current on) in order forthe Gemini 2000 to respondto a Print Request.

–26–

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 thebuilding. The communications lines are run to an Industrialcomputer locatedin the production offices.

[OTHER GEMINIS OR RLC PRODUCTS WITH 20 MA CURRENT LOOP CAN BE CONNECTED IN THE SAME LOOP.]

Note: A Serial Converter Module is

available for interfacing an RS232

device to Geminis.

The drawing below shows the Current Loop set-up. Each Gemini 2000 is given an addressand the Serial DIPswitches are set accordingly. A Baud Rate of 1200 is selected and set in each of the Gemini 2000s. An application program is written, which sends and retrieves data from the units using the Change and Transmit Value commands.

–27–

TROUBLESHOOTING GEMINI SERIAL COMMUNICATIONS

If problems are encountered when trying to get the Gemini(s) and host device or

printer to communicate,the following checklist can beused to help find thesolution.

1. Checkall wiring. Refer to the previous applicationexamples and usethem as a guide to check your serial communication wiring. Proper polarity of all Geminis and otherperipherals must be observed. Ifa multimeter or ammeter is available, insert it inseries in each Serial loop and check for current flow with all units powered up. If no current is flowing, either the loop is not wired correctly, or some other fault has occurred. If too much current has been sent through a Serial Input or Output,the unit may havebeen damaged. If a Gemini is suspected, it can be tested for operation by using the Serial Loop-back test described in the next section.

2. If the Gemini is set-upwith a “host computer”, device or printer, check to make sure that the computer or device is configured with the same communication format as the Gemini. The only communication format the Gemini will accept is; 1 start bit, 7 data bits, odd parity, and 1 stop bit.

3. Checkthe baud rate settings andmake sure all devices inthe loop are set to the same baud rate.

4. Check the Gemini’s unit address. If the Address command is not used when transmitting acommand to theGemini, the Gemini’saddress must be set to 0. See “Sending Commands & Data to the Gemini” section for command structure.

5. If two-way communications are to be established between the Gemini and a computer, try getting the computer to receive transmissions from the Gemini first. The Gemini’s “PRINT REQ.” terminal can be used to initiate the transmissions from the Gemini.

6. When sending commands to the Gemini, the * (2Ah) must terminate the command. NO CARRIAGE RETURNS (0Dh) OR LINE FEED (0Ah) CHARACTERS SHOULD BE SENT TO THE GEMINI. If they are sent, the Gemini will not respond to the next command.

7. Forapplications where 1200 Baud orlower is used, the command terminator (*) can be sent before the string to eliminate any illegally transmitted characters.

SERIAL LOOP-BACK SELF-TEST

The Gemini 2000 has a Serial Loop-back Self-test feature. This test enables the user toverify the operation ofthe Gemini when problemsare encountered tryingto get theGemini and “Hostdevice” communicating. In this test, the Gemini’s Serial Input and Output Loops are connected together with the 20 mA source supplying the loop current. The Gemini then transmits data “to itself”. If the data is received properly, the Gemini2000will change its Scale Factorvalue to 0.1111. Toperform the loop-back test, follow the test sequence as described below.

1. With the unit powered down, wire up the serial terminal block, “TBD”,as

shown in the diagram below.

2. Set the Gemini’sunit address to 15 (set switches 7-10 of theSerial DIP Switch

to the down position).

3. Apply power to the unit. On power-up the Gemini will perform the loop-back

test. To check the results: Call up the Scale Factor value by pressing the “3”

key. If the Serial loop is functioning properly the Scale Factor value will be

0.1111. If this result is not obtained, double check the connections with those

shown in the diagram,and theunit address switch positions and repeat step3.

4. If the connection between the Print Request terminal, “PRINT REQ.” and

“COMMON” is disconnected while the unit is under power, the Scale Factor

value will change back to its previous setting.

If the unit does not pass this test, contact your local Red Lion Controls distributor.

–28–

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

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 theunit is programmed,the settings willbe saved inmemory. The Program Disable “PGM. DIS.” terminal should be connected to “COMM.” to prevent accidental or unauthorized programming changes.

Installation Environment

The unit should be installed in a location that does not exceed the maximum operating temperature and provides good air circulation. Placing the unit near devices that generate excessive heat should be avoided.

The bezel should becleaned only with a soft clothand neutral soap product. Do NOT use solvents. Continuous exposure to direct sunlight may accelerate the aging process of the bezel.

Do not use tools of any kind (screwdrivers, pens, pencils, etc.) to operate the keypad of the unit.

PANEL MOUNTING (Note, See Appendix “B” for Dimensions)

The Gemini is intended to be mounted into an enclosed panel with a gasket to provide a water-tight seal. The unit meets NEMA 4/IP65 requirements for indoor use when properly installed. Two mounting clips and screws are provided for easy installation. Consideration should be given to the thickness of the panel. Too thin ofa panel may distortand not providea water-tight seal.

(Recommended minimum panel thickness is 1/8".)

After the panel cut-out has been completed and deburred, remove the backing from the adhesive side of the gasket, and carefully stick the gasket to the panel. DO NOT THE COUNTER BEZEL. Insert the unit into the panel. As depicted in the drawing, install the screws into the narrow end of the mounting clips. Thread the screws into the clips until the pointed end just protrudes through the other side. Install each of the two mounting clips byinserting the wide lip of the clips into the wide end of the holes located oneither sideof the case. Tighten the screws evenly to apply uniform compression, thus providing a water-tight seal.

CAUTION: Only minimum pressure is required to seal panel. Do NOT

overtighten mounting screws.

–29–

APPLY THE ADHESIVE SIDE OF THE GASKET TO

GEMINI 1000 BLOCK DIAGRAM

–30–

GEMINI 2000 BLOCK DIAGRAM

–31–

SELECT AC POWER (115/230 VAC)

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.

EMC Compliance Installation

This unit complies with the Electromagnetic Compatibility (EMC) standards listed in the specifications.Compliance to the EMC standards was demonstrated by means of a test set-up using the following installation methods:

1. Unit mounted in a metal panel connected to earth ground (protective earth).

2. Shielded (screened)cables for Signal and Controlinputs with shield drain wire

connected to earth ground at the mounting panel only.

Multi-conductor Cable Function Used For

Belden #8771 - 3 conductor, #22 AWG

with foil shield and drain wire

Alpha #2404 - 4 conductor, #22 AWG

with foil shield and drain wire

Alpha #1173C - 3 conductor, #22 AWG

non-shielded

3. Metal bezel of unit connected to mounting panel with 9 inch (23 cm) ground

lead from rear bezel screw. Test: Immunity to ESD per EN 61000-4-2.

4. EMI filter (Shaffner FN610) placed on the DC mains cable for EMI

frequencies above 40 MHz when using optional power supply. Test: RF

Conducted Immunity EN 61000-4-6

Input A, Input B, PGM DIS,

and REM RST

20 mA serial option

Relay Outputs and

Solid State Outputs

Shield Termination

EMC compliance installation testing had the drain wire for the shielded cable

terminated as shown. The drain wire was less than 0.5" (12.7 mm) long.

–32–

Additional EMC Installation Guidelines

Although this unit is designed with a high degree of immunity to ElectroMagnetic Interference (EMI), proper installation and wiring methods must be followed to ensure compatibility in each application. The type of the electrical noise, source or coupling method into the unit may be different for various installations. Listed below are some additional EMC guidelines for successful installation in an industrial environment.

1. The unit should be mountedin a metal enclosure, which is properly connected

to protective earth.

a. If the bezel is exposed to high Electro-Static Discharge (ESD) levels,

above 4Kv, it should be connected to protective earth. This can be done by making sure themetal bezel makes proper contact to the panelcut-out or connecting the bezel screw with a spade terminal and wire to protective earth.

2. Use shielded (screened) cables for all Signal and Control inputs. The shield

(screen) pigtail connection should be made as short as possible. The

connection point for the shield depends somewhat upon the application.

Listed below are the recommended methods of connecting the shield, in order

of their effectiveness.

a. Connect the shield only at the panel where the unit is mounted to earth

ground (protective earth).

b. Connect the shield to earth ground at both ends of the cable, usually

when the noise source frequency is above 1 MHz.

c. Connect the shield to common of the unit and leave the other end of the

shield unconnected and insulated from earth ground.

3. Never run Signal or Control cables in the same conduit or raceway with AC

power lines, conductorsfeeding motors, solenoids, SCRcontrols,and heaters,

etc. The cables should be run in metal conduit that is properly grounded. This

is especially useful in applications where cable runs are long and portable

two-way radios are used in close proximity or if the installation is near a

commercial radio transmitter.

4. Signal or Control cables within an enclosure should be routed as far away as

possible from contactors, control relays, transformers, and other noisy

components.

5. In extremely high EMI environments, the use of external EMI suppression

devices, such as ferritesuppression cores, is effective. Install themon Signal and

Control cables as close to the unit as possible. Loop the cable through the core

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. The following EMI suppression devices (or equivalent) are recommended: Ferrite Suppression Cores for signal and control cables:

Fair-Rite # 0443167251 (RLC #FCOR0000) TDK # ZCAT3035-1330A Steward #28B2029-0A0

Line Filters for input power cables:

Schaffner # FN610-1/07 (RLC #LFIL0000) Schaffner # FN670-1.8/07 Corcom #1VR3

Note: Reference manufacturer’s instructions when installing a line filter.

6. Long cable runs are more susceptible to EMI pickup than short cable runs. Therefore, keep cable runs as short as possible.

7. Switching of inductive loads produces high EMI. Use of snubbers across inductive loads suppresses EMI. Snubbers: RLC #SNUB0000

WIRING CONNECTIONS

After the unit has been mechanically mounted, it is ready to be wired. All

conductors should meet voltage and current ratings for each terminal. Also cabling should conformto appropriate standards ofgood installation, local codes and regulations. Itis recommended that powersupplied to the unit (ACor DC) be protected by a fuse or circuit breaker.

All wiring connectionsare made on removableplug-in terminal blocks. Thereis

a separate terminal block for the count inputs, bottom board, optional relay board, and optional20 mA current loop. Whenwiring the unit, remove the terminal block and refer to the “Block Diagram” to identify the terminal block position number with the proper function. Simply strip the wire, leaving approximately 1/4" bare wire exposed(standardwires should betinnedwith solder). Insertthe wire into the terminal andtighten down thescrew until wireis clamped intightly. Each terminal can accept up to two 18-gage wires. After the terminal block is wired, install in proper location on board. Wire each terminal block in this manner.

–33–

PRIMARY A.C. POWER WIRING

For best results,the A.C. primary power shouldbe 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 poweris connected to thebottom left terminals TBA1&2,marked asAC Power, 50/60 Hz. The voltage selector switch, located on the side of the unit, is used to select the proper voltage. The switch is a slide movement type and can be set by using asmallscrewdriver. If the switchis towards the frontof the unit,itis set for230 VAC input. Theswitch is in the 230VAC position when shipped fromthe factory.

Note: Beforeapplying power to theunit, make surethe AC power selector switch

is set for the proper voltage setting.

USING AN EXTERNAL POWER SOURCE

The Gemini can be operated from a D.C. power source that provides 11-14 VDC at the units rated power consumption. The power source can be a 12 V battery or an external power supply that is capable of supplying the unit’s rated current. It is not necessary to provide battery backupto retain count information. The Gemini has an internal memory in which the count is stored upon power-down. Refer to the “Block Diagrams”.

Relay Wiring

To prolong contact life and suppress electrical noise interference due to the switching of inductive loads, it is good installation practice to install a snubber across the contactor. Follow the manufacturer’s instructions for installation.

Note: Snubber leakage current can causesome electro-mechanical devicesto be

held ON.

SERIAL COMMUNICATIONS

The Gemini 2000 can be purchased with 20 mA Current Loop Option. On these units, refer to the 20 mA Current Loop section for installation and operational procedures of the Serial loop.

INPUT A & MAGNETIC PICKUP INPUT

The Magnetic Pickup Input and Input A utilize some common circuitry. For this reason the Input A switches are used to set up both Magnetic Pickup and Logic Input A. S1 selects between Magnetic Pickup Input or Logic Input A. WHEN THEMAGNETIC PICKUP INPUTIS BEING USED,S2 MUST BE IN THE SNK POSITION or the unit will not count.

S3 (HI/LO FRQ) and S4 (HI/LO BIAS) do not affect the Magnetic Pickup Input. When S1 is in the Logic position, the Magnetic Pickup Input is disabled and Input A can be used.

INPUT B

Input B is designed specifically for Logic type inputs. It is identical to the count input of SC Series counters. When Input A is set up for Logic operation, both InputA and Input B operateidentically. S5, S6, and S7 function the sameas S2, S3, and S4.

–34–

INSTALLATION & REMOVAL OF THE RELAY BOARD

To install the relay board, locate the relay opening at the lower right-hand corner, on the back of the Gemini. Pull the tab down while sliding the board into the two slots in the housing. The relay board will seat into the unit, allowing the tab to return to its original position. To remove the relay board, pull down on the tab just enoughto allow the relayboard to slide out.Grasp the terminal connector and slowly pull until the relay board is removed.

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 andinternal load variations. AllRLC 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. Since the “LO FRQ” mode also provides very high immunity against electrical noise pickup, it is recommended that this mode also be used, whenever possible,with electronic sensor outputs. The “LO FRQ” mode can be used with any type of sensor output, provided pulse widths never decreasebelow 5 msec, andthe count rate does not exceed 100 cps.

3. V

and VIHlevels given are nominal values +/-10% when the voltage on “DC

OUT” terminal is +12 VDC. These nominal values will vary in proportion to the variations in the “DC OUT” terminal voltage, which are caused by line voltage and load changes.

4. When shielded cable is used, the shield should be connected to “COMM.” at the counter and left unconnected at the sensor end.

5. Input B set-upis identicalto that of Input A. Input Bis for Logic Inputs only.

6. Inputs A and B can accept source pulses from other circuits up to +28 V in amplitude. For voltages above +28 V, a limiting resistor and zener diode should be used to limit the voltage at the input.

–35–

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

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. The functions of these switches are as follows:

S1 - MAG: Enables the Magnetic Pickup terminal to be used.

LOGIC: Disables the Magnetic Pickup Input.

Note: SWITCH S2 MUST BE IN THE “SNK” POSITION FOR MAGNETIC PICKUP INPUT.

S2 - SNK: Provides a 7.8 K pull-up resistor for sensors with sinking

outputs. SRC: Provides a 3.9 K pull-down resistor for sensors with sourcing outputs.

S3 - HI FRQ: Removes damping capacitor and allows operation up to 10

KHz. Minimum count ON/OFF times - 50 usec. LO FRQ: Connects damping capacitor for switch contact debounce. Limits count speedto 100 cpsmax. Min. count pulseON/OFF time - 5 msec.

S4 - HIBIAS: Sets inputtrigger levels at mid-range to accept outputsfrom

2-wire proximity sensors, resistive photo-cells, and logic pulses with full 0 to +12 V swings. (V LO BIAS: Sets input trigger levels to the low range to accept logic pulses with 0 to 5 V swings. (V

S5 - Same as S2, for Input B - does not affect Magnetic Pickup Input. S6 - Same as S3, for Input B. S7 - Same as S4, for Input B.

CHAN. B CHANNEL A

S8 - DIS. RST.: Disables front panel reset.

EN. RST.: Enables front panel reset if “Operator Accessible

Functions” mode (Code 66) has Reset enabled.

= 5.5 V, VIH= 7.5 V)

= 1.5 V, VIH= 3.75 V)

–38–

GEMINI 2000 SENSOR INPUT CONNECTIONS & INPUT CONFIGURATION SWITCH SET-UP

S1 - MAG: Enables the Magnetic Pickup terminal to be used.

LOGIC: Disables the Magnetic Pickup Input.

Note: SWITCH S2 MUST BE IN THE “SNK” POSITION FOR MAGNETIC PICKUP INPUT.

S2 - SNK: Provides a 7.8 K pull-up resistor for sensors with sinking

outputs. SRC: Provides a 3.9 K pull-down resistor for sensors with sourcing outputs.

S3 - HI FRQ: Removes damping capacitor and allows operation up to

10 KHz. Minimum count ON/OFF times - 50 usec. LO FRQ: Connects damping capacitor for switch contact debounce. Limits count speed to 100 cps max. Min. count pulse ON/OFF time 5 msec.

S4 - HIBIAS: Sets inputtrigger levels at mid-range to accept outputsfrom

2-wire proximity sensors, resistive photo-cells, and logic pulses with full 0 to +12 V swings. (V LO BIAS: Sets input trigger levels to the low range to accept logic pulses with 0 to 5 V swings. (V

S5 - Same as S2, for Input B - does not affect Magnetic Pickup Input. S6 - Same as S3, for Input B. S7 - Same as S4, for Input B. S8 - DIS. RST.: Disables front panel reset.

CHAN. B CHANNEL A

EN. RST.: Enables front panel reset if “Operator Accessible Functions” mode (Code 66) has Reset enabled.

= 5.5 V, VIH= 7.5 V)

= 1.5 V, VIH= 3.75 V)

–39–

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 E

information and count value when power is removed or interrupted.

5. INPUTSA AND B:Switch selectable toaccept count pulsesfrom a varietyof

sources including switch contacts, outputs from CMOS or TTL Circuits, and

all standard RLC sensors.

Current Sourcing - Unit provides 3.9 KW pull-down load for sensor with

current sourcing outputs. (Max. input voltage = 28 VDC @ 7 mA.)

Current Sinking- Unit provides 7.8KW pull-up loadfor sensors withcurrent

sinking outputs. (Max. sensor current = 1.6 mA.)

Debounce -Damping capacitor provided for switch contact debounce. Limits

count rate to 100 Hz max. With 50% duty cycle.

Lo Bias - Input trigger levels V

Hi Bias - Input trigger levels V

Note: Bias levels given are ±10% @ 12 VDC. They vary proportionally with

sensor supply voltage.

6. MAGNETIC PICKUP INPUT:

Sensitivity - 150 mV peak nominal

Hysteresis - 100 mV nominal

PROM memory retains all programming

= 1.5 V, VIH= 3.75 V

= 5.5 V, VIH= 7.5 V

Input impedance - 26.5 KW @ 60 Hz nominal Maximum Input Voltage - ±50 Vp

7. MAXIMUM COUNT RATES: Uni or Bi-Directional Modes - 9 KHz, 8 KHz (X2)

2-Input Anti-Coincidence Modes - 5 KHz, 4 KHz (X2)

Quadrature Modes - 5 KHz (X1), 4 KHz (X2 or X4) Rate Indicator Version - 10 KHz, 8 KHz (X2)

8. CONTROL INPUTS: Reset - Activelow (V

3 mA), Response time = 10 msec. Program Disable - Active low (V VDC (I Print Request - (GEM 2 only) Active low (V

SNK

= 1 mA).

pulled up to +5 VDC (I

9. SERIAL COMMUNICATIONS (Optional Gemini 2000 only):

= 1.5 Vmax.), internally pulled up to+12 VDC (I

= 1.5 V max.), internally pulled up to +5

= 1.5 V max.), internally

SNK

= 1 mA).

Type - Bi-directional 20mA current loop, 20 mA source provided.(Powers up to 7 units in a loop with internal current source.)

Baud Rate - Programmable 300 to 2400. Maximum Address - 16 units (0 to 15). (Actual number in a single loop is

limited by serial hardware specifications.) Data Format - 10bit frame, Odd parity (one start bit,7 data bits, one odd parity bit, and one stop bit.)

SNK

DIMENSIONS In Inches (mm)

Note: Mounted units require a clearance of 6.8" (W) behind the panel.

–40–

9. SERIAL COMMUNICATIONS (Optional): (Cont’d) Serial Hardware Specifications -

SO - Output Transistor Rating:V

(Can address 16 units in a loop)

SI - Input Diode Rating: V

Note: The compliance voltage rating of the source must be greater than the

MAX

= 1.25 V

= 30 VDC, V

; 1.5 V

TYP

SAT

MAX

=1V

MAX

at 20 mA.

sum of the voltage drops around the loop.

10. OUTPUT(S): Solid-State - Currentsinking NPN open collectortransistor(s).I

maximum. V 1 VDC max. @ 100 mA.

= 30 VDC maximum (Internal Zener diode protected).VOL=

SNK

= 100 mA

Relay(s) - Mountedon a field replaceable P.C.board. Form C contactsratedat 5 amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 H.P. @ 120 VAC (inductive load). The operate time is 5 msec. nominal and the release time is 3 msec. nominal.

Relay Life Expectancy - 100,000 cycles at Max. Rating. (As load level decreases, life expectancy increases.)

Programmable Timed Outputs - The timed outputs can be set from 0.01 to

599.99 seconds, ±(0.01% + 10 msec).

11. CERTIFICATIONS AND COMPLIANCES:

SAFETY

IEC 1010-1, EN 61010-1: Safety requirements for electrical equipment

for measurement, control, and laboratory use, Part 1. IP65 Enclosure rating (Face only), IEC 529 Type 4 Enclosure rating (Face only), UL50

ELECTROMAGNETIC COMPATIBILITY:

Immunity to EN 50082-2

Electrostatic discharge EN 61000-4-2 Level 2; 4 Kv contact

Level 3; 8 Kv air

Electromagnetic RF fields EN 61000-4-3 Level 3; 10 V/m

80 MHz - 1 GHz

Fast transients (burst) EN 61000-4-4 Level 4; 2 Kv I/O

Level 3; 2 Kv power

RF conducted interference EN 61000-4-6 Level 3; 10 V/rms

150 KHz - 80 MHz

Power frequency magnetic fields EN 61000-4-8 Level 4; 30 A/m

Emissions to EN 50081-2

RF interference EN 55011 Enclosure class A

Power mains class A

Notes:

1. Metal bezel ofunit connected with ground from rear bezelscrew tometal mounting panel.

2. When the unit is DC powered, a power line filter (RLC# LFIL0000 or equivalent) was installed, so as not to impair the function of the unit.

Refer to the EMC Compliance Installation section of the manual for

additional information.

12. ENVIRONMENTAL CONDITIONS: Operating Temperature: 0 to 50°C Storage Temperature: -40 to 80°C Operating and Storage Humidity: 85% max. relative humidity

(non-condensing) from 0°C to 50°C.

Altitude: Up to 2000 meters

13. CONSTRUCTION: Metal die-cast bezel, plastic case. This unit is rated

for NEMA 4/IP65 indoor use. Installation Category II, Pollution Degree 2.

14. WEIGHT: 2.1 lbs (0.9 kg)

–41–

APPENDIX “C” - TROUBLESHOOTING GUIDE

The majority of difficulties arising withthe 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 orAC connections may resultin permanent damage

to the unit.

For further technical assistance,contact technicalsupport at the numbers listed on theback cover of the instruction manual.

PROBLEM POSSIBLE CAUSE REMEDIES

NO DISPLAY 1. Power off, improperly connected, or power 1. Check all wiring, verify power.

P ON DISPLAY 1. Data error on power-up. 1a. Press “E” key.

E ON THE DISPLAY 1. Data error detected by processor. 1a. Press “E” key.

RIGHT HAND DIGITS LOCKED TO ZERO 1. Right-hand zeros programmed. 1. Check function code 61 for dummy “0”

NO RESPONSE TO FRONT PANEL 1. Panel disabled. 1. Consult manual on “Operator Accessible

UNIT DOES NOT COUNT 1. No input. 1. Check sensors/connections.

brown-out.

b. Check all function codes.

b. Check all function codes. c. Check signal lines for possible noise sources.

program.

Functions” modes.

2. Input selected incorrectly. 2. Check rear panel DIP switches.

3. Wrong Personality. 3. Check function code 41 for counter mode.

4. Count Inhibit. 4. Check function code 43. If set for 1, when Input B is low, count is inhibited.

5. If in Rate Mode, sample time not complete. 5. Allow sample time to complete

6. Scale Factor / Multiplier too small. 6. Check scale factor value and scale multiplier

values.

–42–

APPENDIX “C” - TROUBLESHOOTING GUIDE (Cont’d)

PROBLEM POSSIBLE CAUSE REMEDIES

UNIT WILL NOT ACCEPT THE DESIRED PRESET VALUE

UNIT COUNTS INCORRECTLY 1. Input type incorrectly selected. 1. Check rear panel DIP switches. Turn on

UNIT WILL NOT RESET 1. Front panel reset disabled. 1. Check rear panel DIP switch.

DATA VALUES & FUNCTIONS WILL NOT CHANGE OR NOT RECORDED

UNIT CHANGES FUNCTION OR MODE “BY ITSELF”

CANNOT PROGRAM CODE 43 (INPUTS A & B RESPONSE MODES)

CANNOT PROGRAM CODE 51 - 2, 3, 4, 5, 6 1. Unit is in rate or boundary mode. Code 51 is

1. When scale factors greater than 1 are used,

the preset value must be evenly divisible by the scale factor value.

2. Inputs incorrectly connected or loose connections. 2. Check sensors/input connections.

3. Electrical interference. 3. Check connections and wiring for noise sources.

4. Wrong counting mode. 4. Verify functions and modes.

5. Scale factor incorrect. 5. Change scale factor value.

2. Reset disabled. 2. Check function code 66.

1. Front panel locked out. 1. Consult manual on “Operator Accessible

2. Incorrect procedures (“E” not pressed) 2. Consult manual on programming.

1. Incorrect programming procedure 1. Consult manual on programming functions in

1. Unit is in tachometer mode. 1. Check function Code 41.

automatically set to 1.

1. Unit automatically adjusts preset value to be evenly divisible by the scale factor value.

LO FRQ. switch for count speed of less than 100 cps.

Functions” Mode (66)

sequential order.

1. Change 54 then program 52.

–43–

APPENDIX “C” - TROUBLESHOOTING GUIDE (Cont’d)

PROBLEM POSSIBLE CAUSE REMEDIES

CANNOT PROGRAM CODE 52-1,2 1.54-6isprogrammed. 1. Change 54 then program 52.

CANNOT PROGRAM CODE 52 - 6 1. 54 - 1, 2 is programmed. 1. Change 54 then program 52.

CANNOT PROGRAM CODE 54 - 1, 2 1. 52 -6 is programmed. 1. Change 52 then program 54.

CANNOT PROGRAM CODE 54 - 6 1. 52 -1, 2 is programmed. 1. Change 52 then program 54.

CANNOT PROGRAM CODE 63 (Sample Time)

OUTPUT DOES NOT TERMINATE AT MANUAL RESET END

Note: For Serial Communication problems refer to “Troubleshooting Gemini Serial Communications” section.

2. Unit is in tachometer mode.

1. Unit is in Counter mode. 1. Check function Code 41.

1. Reset mode set for “Momentary” reset. 1. Change reset mode to “Maintained” reset (51).

–44–

APPENDIX “D” - GEMINI FUNCTION COMMAND CODE SUMMARY

CODE MODE DESCRIPTION COMMENTS

41 UNIT PERSONALITY

1 Counter

2 Rate Automatically selects [511], [52 6] &[54 6] if [541,2]or[52 1,2] was

43 INPUTSA&BRESPONSE MODES (counter only)

1 Count with Inhibit Input A = Count, Input B = Inhibit

2 Count with Up/Down Control Input A = Count, Input B = Up/Down

3 Input Anti-Coincidence Add/Subtract Input A = Add, Input B = Subtract

4 Input Anti-Coincidence Add

5 Quadrature

6 Quadrature x4

44 NUMBER OF COUNT EDGES Cannot be programmed in Quad x4.

1 1 Count on falling edge of count input.

2 2 Count on both edges of count input.

45 SCALE MULTIPLIER

2 0.1

3 0.01

4 0.001

46 DECIMAL POINT & LEADING ZERO BLANKING

- (+) Leading Zero Blanking Enabled

- (-) Leading Zero Blanking Disabled *

+/-1 No Decimal Point

+/-2 Decimal Point Right of Digit 2

+/-3 Decimal Point Right of Digit 3

+/-4 Decimal Point Right of Digit 4

+/-5 Decimal Point Right of Digit 5

+/-6 Decimal Point Right of Digit 6

*Polarity sign is displayedin frontof the identifier, a (-) sign isdisplayed, a (+) sign is not.

–45–

programmed.

APPENDIX “D” - GEMINI FUNCTION COMMAND CODE SUMMARY (Con’t)

CODE MODE DESCRIPTION COMMENTS

51 RESET MODES

- (+) Maintained Unit will remain reset as long as reset is activated.

- (-) Momentary Unit will reset instantly and will start counting again even if reset is still

+/-1 Manual to zero Automatically selected when Rate or Boundary [54 6],is programmed,

+/-2 Manual to Preset ** +/-3 Auto to Zero after Output Time Delay ** Output activates at Preset ** +/-4 Auto to Preset after Output Time Delay ** Output activates at zero. ** +/-5 Auto to Zero at Preset ** +/-6 Auto to Preset at Zero **

52 OUTPUT 1 TERMINATION

- (+) Normal Phase Output normally “OFF”, turns “ON” at preset.

- (-) Reverse Phase* Output normally “ON”, turns “OFF” at preset.* +/-1 Terminate at Output 2 Start (Gemini 2000 Only) +/-2 Terminate at Output 2 End (Gemini 2000 Only) +/-3 Terminate at Manual Reset +/-4 Terminate at Manual Reset End +/-5 Terminate after Output 1 Time Delay +/-6 Boundary

53 NA OUTPUT 1 TIME DELAY Range 0.01 to 599.99 sec. 54 OUTPUT 2 TERMINATION (Gemini 2000 Only)

- (+) Normal Phase Output normally “OFF”, turns “ON” at preset.

- (-) Reverse Phase* Output normally “ON”, turns “OFF” at preset.* +/-1 Terminate at Output 1 Start +/-2 Terminate at Output 1 End +/-3 Terminate at Manual Reset +/-4 Terminate at Manual Reset End

*Polarity sign is displayed in front of the identifier, a (-) sign is displayed, a (+) sign is not.

** For the Gemini 2000, all reset to preset modes reset to preset 2 and Output refers to Output 2.

activated.*

all others are locked out.

–46–

APPENDIX “D” - GEMINI FUNCTION COMMAND CODE SUMMARY (Con’t)

CODE MODE DESCRIPTION COMMENTS

54 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.

61 RIGHT-HAND DUMMY ZEROS

1 1 Dummy Zero

2 2 Dummy Zeros

3 3 Dummy Zeros

4 No Dummy Zeros

63 SAMPLE TIME IN SECONDS (rate only)

410

520

650

66 “OPERATOR ACCESSIBLE FUNCTIONS” MODES “PGM DIS” Terminal connected to “COMM.”

- (+) Reset Button & “RST” Terminal Enabled Front panel reset can be independently disabled by using DIP switch.*

- (-) Reset Button & “RST” Terminal Disabled* Both front panel and rear terminal are disabled

+/-1 No Functions Enabled

+/-2 Preset Programming Enabled

+/-3 Scale Factor Programming Enabled

+/-4 Preset & Scale Factor Programming Enabled

1 NA PRESET 1

2 NA PRESET 2

3 NA SCALE FACTOR Up to +/-5.9999

*Polarity sign is displayed in front of the identifier, a (-) sign is displayed, a (+) sign is not.

Up to +/-999999

-47-

APPENDIX “E” - SCALING FOR RATE INDICATION

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 areavailable 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. At the end of the sample time period selected, the unitdisplays the pulses accumulated after they have been internally multiplied bya programmable scale factor. The unit maintains this display until it is updated by the next successive sample time period. This is an automatic process that provides a very convenient and adaptable method for rate indication applications.

The first step in determining the sample time and scale factor to be programmed is to calculate the pulses per second (PPS) generated by the application set-upat a known processrate. The standardformula for determining PPS at a known process rate or machine speed is:

Revolutions/Minute (RPM) x Pulses/Revolution (PPR)

This formula is anexcellent starting point, and will work inmany applications; however, applications willoccur that do notfit this formula. Inthese cases, it will require simple deductions to determine the correct PPS.

The next step is to choose a sample time to be programmed from those available (1, 2 ,5, 10, 20, and 50 seconds).

The following guidelines apply:

1. The sampletimeis also the display updatetime. Unless the application dictates

a longer update time (i.e. greater precision or fewer display changes), the

basic rule is to start the calculation process with a one-second sample time.

2. When usingthe Gemini as a controlmechanism, it is imperative thatthe update

time be shorter than the maximum allowable control reaction time. This is

another reason to begin with the one-second sample time.

FORMULA [A]

60 Seconds

= PPS

APPLICATION EXAMPLE [A]

PARAMETERS AT MONITORED SPEED A) Speed of shaft - 1200 RPM B) Gear teeth per revolution - 50 C) Web sped at 1200 RPM - 820 FPM D) Desired Readout - FPM

To begin the process of determining the sample time and scale factor, the parameters from application (A)shouldbe inserted into Formula (A) todetermine the PPS:

The nextstep is to choosea scale factor, thatwhen multiplied by 1000willcause a display of 820. The following formula will produce the correct scale factor:

Thus, by programminga scale factor of 0.8200, theGeminiis now set todisplay the correct FPM readout throughout the entire process, as it varies in speed.

A majority of the applications will be completed with a one-second sample time. The following guidelines(next page) will assist in varying the sample time and other factors, if the calculated scale factor exceeds the 5.9999 scale factor capability of the Gemini.

1. Reviewthe applications to ascertain ifmore input pulses can begenerated. In all

rate indication applications, itis best to generate the highestpulse rate possible.

2. If the scale factor is calculated to be between 6.0000 and 11.9998, Function

Code 44 (number ofcount edges) may be programmed [44 2],which will allow

the calculated scale factor to be divided by 2.

3. If the scale factor isover 5.9999, the sample time may be increased to a higher

level (2,5,10,20,or 50 seconds). Keep inmind the update display timeand the

control requirements of the application.

RPM x PPR

Desired Reading

PS x Sample Time

1000 x 1

= PPS =

60 60

FORMULA [B]

820

= Scale Factor = 0.8200

1200 x 50

= Scale Factor

= 1000 PPS

–48–

4. Any calculated scale factor may be divided by a factor of 10, by programming Function Code 61 (dummy right-hand zeros) to [61 1], which will display a constant zero in the least significant digit.

(Note: This decreasestheprecision of the displayfrom +/-1 digit to +/-10digits.)

The same procedure may be accomplished for 100 and 1000 with [61 2] and [61 3].

The use of one or more of the above capabilities will solve most applications

where the calculated scale factor value exceeds 5.9999.

There are two other considerations that should be discussed concerning

sample time and scale factor calculations.

1. Occasionally, the input pulse rate will greatly exceed the desired readout, and this mayresult in a scale factorwith only 1 or 2significant digits programmed into the Gemini. For example, assume a calculated scale factor of 0.003246. Instead of programming 0.0032, the Function Code 45 (scale multiplier) is programmed [45 3], which multiplies the input pulses by 0.01 and allows the scale factor of 0.3246 to be used. This increases the precision by adding two additional significant digits.

2. In applications where greater precision is desired, it may be necessary to use a longer sample time.Thiswill take a larger sampleof incoming pulses, and will in fact result ingreater precision. (In most cases, theinput pulses available will

allow for +/-1 digit precision even at the one-second sample time level.)

APPLICATION EXAMPLE [B]

The shaft of a positive displacement pump has a 14-tooth sprocket that is being

sensed byan LMPC0000. The unit ispumping 810 liters of water per minute when the shaft is turning 400 RPM. The desired readout is in liters per minute (LPM).

RPM x PPR

CALCULATING SCALE FACTOR AT 1-SECOND SAMPLE TIME

Desired Readout

PPS x Sample Time Factor 93.33 x 1

CALCULATING PPS

= PPS =

60 60

400x14

= Scale =

= 93.33 PPS

810

= 8.68

In this application,the 5.9999 scale factorhas been exceeded. Tocomplete 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.

APPLICATION EXAMPLE [C]

In this application, a photo-cell sensor is being used to count each bottle as it moves along a bottling process. The requirement is to display bottles per minute (BPM). There is no rotary motion that can be sensed to gain a greater input pulse rate. Normal rate is 400 BPM.

The PPSformula does not fit this application. In this case, in order to calculate PPS, the 400 BPM rate is simply divided by 60 seconds.

400 BPM

60 seconds

First, the 6.66 PPS is factored into Formula (B), using a one-second sample time.

2000 capabilities will be necessary.

indicates that a sample time of 10 should be tried next.

Code 44 to bring this scale factor value within the unit’s range. Simply divide

6.0060 by 2 and program 3.0030 into the scale factor. Then program Function Code 44 (number of count edges) to [44 2] to double the input pulse rate. The Gemini will now update every 10 seconds, and indicate the correct BPM rate.

grouped together to solve a special rate indication application.

Desired Readout

PPS x Sample Time Factor 6.66 x 1

The 60.06 is well above the 5.9999 capability, and the use of other Gemini

The magnitude of difference between the calculated scale factor and 5.9999

5.9999

Desired Readout

PPS x Sample Time Factor 6.66 x 10

This isjust above the 5.9999 scale factor range;however, we canuse Function

This application demonstrates how the various Gemini capabilities can be

= Scale =

60.06 = 10.01 - Sample Time 10 seconds

= 6.66 PPS

400

= Scale =

= 60.06 Scale Factor

400

= 6.0060

–49–

-50-

–51–

-52-

-53-

APPENDIX “G” - ORDERING INFORMATION

MODEL NO. DESCRIPTION OPTIONS PART NUMBERS

W/Relay Board W/20 mA Current Loop 115/230 VAC

GEM1 Gemini 1000 Yes No GEM10060

GEM2 Gemini 2000 Yes No GEM20060

Yes Yes GEM20160

For Informationon Pricing, Enclosures, Base MountKits, & Panel Adapter Kits, refer to theRed Lion Controls Catalog or contact your local RLC distributor.

Gemini 1000 Relay Board RLYBD000

Gemini 2000 Relay Board RLYBD002

–54–

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-55-

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-56-

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. The Company disclaims all liability for any affirmation, promise or representation with respect to the products.

The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against damages, claims, and expenses arising out of subsequent sales of RLC products or products containing components manufactured by RLC and based upon personal injuries, deaths, property damage, lost profits, and other matters which Buyer, its employees, or subcontractors are or may be to any extent liable, including without limitation penalties imposed by the Consumer Product Safety Act (P.L. 92-573) and liability imposed upon any person pursuant to the Magnuson-Moss Warranty Act (P.L. 93-637), as now in effect or as amended hereafter.

No warranties expressed or implied are created with respect to The Company’s products except those expressly contained herein. The Customer acknowledges the disclaimers and limitations contained and relies on no other warranties or affirmations.

Red Lion Controls 20 Willow Springs Circle York PA 17402 Tel +1 (717) 767-6511 Fax +1 (717) 764-0839

Red Lion Controls BV

Basicweg 11b NL - 3821 BR Amersfoort Tel +31 (0) 334 723 225 Fax +31 (0) 334 893 793

GEM2 / IM - M 4/05 DRAWING NO. LP0098

Red Lion Controls AP

31, Kaki Bukit Road 3,

#06-04/05 TechLink

Singapore 417818

Tel +65 6744-6613

Fax +65 6743-3360

Red Lion GEMINI 2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual