red lion GEMINI 1000, GEMINI 2000 Instruction Manual

THE ASTRO LINE SERIES

GEMINI 1000/2000 INSTRUCTION MANUAL

GEM1&2CVR.QXD 4/10/02 11:04 AM Page 1

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.

GEM1&2CVR.QXD 4/10/02 11:04 AM Page 2

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 Applications ............................................ 27-28

Troubleshooting Gemini Serial Communications .................................. 29

Serial Loop-Back Self-Test ............................................. 29

V. APPENDIX “A” - INSTALLATION & INPUT CONFIGURATION SWITCH SET-UP ............... 30-40

VI. APPENDIX “B” - SPECIFICATIONS & DIMENSIONS .............................. 41-42

VII. APPENDIX “C” - TROUBLESHOOTING GUIDE ................................ 43-45

VIII. APPENDIX “D” - FUNCTION COMMAND CODE SUMMARY ......................... 46-48

IX. APPENDIX “E” - SCALING FOR RATE INDICATION .............................. 49-50

X. APPENDIX “F” - GEMINI 1000/2000 PROGRAMMING CHARTS ........................ 51-54

XI. APPENDIX “G” - ORDERING INFORMATION .................................. 55

TABLE OF CONTENTS

GENERAL DESCRIPTION

The Gemini is a two input, microprocessor-based device which offers the
features and performance ofa 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 internal precision 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 panel switch settings,any one of 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
E

2

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 verifythe integrity of the storeddata. There is also aself-test mode
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 for washdownand/ordust.Electrical connections are made
with removable, plug-in terminal strips at the rear of the unit. Clamp type
pressure plate terminals accept stripped #14 AWG wire without lugs.

As a counter, the Geminican 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. Both channelsof count information are monitored
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 set as 1, 2, 5, 10, 20, or 50 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)arealso 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) can have a value ranging from -999999 to +999999.
Decimal placement will be the same as the decimal placement on the input value.

Various resetmodes can beselected: manual resetto 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 to directlycommand motors, valves, or otheractuators 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 modesare then setby pressing theappropriate
keys asindicated by the embossed numbersabove them. A functionis 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.

Data forthe presets, scale factor, and time delaysare entered differently. Each
digit key controls the digit on the display directly above it. Changing the digits
can bedone by repeatedlypressing the key beneath the digit positionyou wish to
change orby merely holding it down.As you hold itdown 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 as indicated by the
embossed number above it. 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 normaloperatingmode using the old functionand
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 majorpersonality is functioncode 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, press the “SF” (3) key. The
display 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 new value will be entered when the “E” key is
pressed. This key must be held down until the display has
blanked after whichtheunit will return to the normaldisplay
mode.

The internal countvalue is multiplied bythescale factor value, whichchanges
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.

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 mustbe generated per measuring unit.For example, if 5 pulses
are being received per foot of material, the precision of 10th of feet cannot be
attained by simply programming a 2.00 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 oddpreset value is entered, such as 6.7 ft., the Geminiwill alter
the preset display to read in even tenths of feet.

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

The preset level is changed in the same way as the scale
factor. Pressing the “P” (1) key will display the present
value 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 integermultiple 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 values can be set from .01 to 599.99 seconds.

To change output1 time delay, enter function code53and
enter the new value by holding down or repeatedly pressing
the key below the digit position you wish to change.

The new value will be entered when the “E” key is pressed
and the display will immediately return to the count value.

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 otherfunctions, 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.

FACTORY SETTINGS

Keys Struck Display Description

4,1 41 1

Personality selected as Counter

4,3 43 1

Count with Inhibit

4,4 44 1

Count on one edge of input (no doubling)

4,5 45 1

Scale Multiplier of 1.0

4,6 46 1

Leading zero blanking and no decimal point

5,1 51 1

Manual reset-to-zero, aslong as buttonremainsPUSHED

5,2 52 3

Output 1 terminates at Reset, Normal Output Phase

5,3 0000.10

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.

*5,4 54 3

Output 2 terminates at Reset, Normal Output Phase.

*5,5 0000.10

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.

6,1 61 4

No right-hand dummy zeros

6,6 66 4

Reset enabled along with scale factor and presets.

SF(3) 01.0000

Scale Factor set to unity

P(1) 000500

Preset 1 value equals 500

*P(2) 001000

Preset 2 value equals 1000

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

programmed as shown above.

*Applies to the Gemini 2000 only.

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 canbe prevented. However, itmaybe 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 enable thesefunctions even when 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 AND RESETENABLED- The entire front

panel is disabled with the exceptions of preset programmability and

manual reset. All functions can be interrogated.

3. SCALE FACTOR PROGRAMMING AND RESET ENABLED - The

entire front panel is disabled with the exceptions of scale factor

programmability and manual reset. All functions can be interrogated.

4. SCALE FACTOR AND PRESET PROGRAMMING, AND RESET

ENABLED - The entirefrontpanel is disabled with the exceptionsofscale

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 is independentofthe rear terminal remotereset,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 power is turned off, on purpose or by accident, all pertinent
function settings and measurements are automatically saved.Then, when poweris
restored, the function and data are re-instated. This allows you to program a
Gemini once and not have to re-program it until you wish to use it in another mode.

When the function codes and data are saved, computations are made with
these values.The result of thesecomputations is stored in the memory to serve as
a check against possible error. Then on power up, the same computations are
repeated on thestored data. If theresults do not agree withthe stored 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 timingofinternalevents does not occur, an“E”willappear on the left sideofthe
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 the accumulation ofcounts or control functions. A function code of
“6” “+/-” starts the test. At this time, whatever wasdisplayed will be replaced by
a string ofdecimal points and the overflowindicator. Then, the display willshow
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 off the overflow indicator and activate the minus(-) sign. After this,
the unit showsaninterlace 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 “P” (1) and “P” (2) keys.

(The program disable pin must be high in order to allow activation of the
output.)
Note: During selftest caution should be used whentestingthe outputs so as not to

cause any undesirable or hazardous conditions in the system.

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 digit and above thepolarity 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 benoted that the useof 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. But if theinternalcount value is exceeded, thenthis
value may no longer be valid.

PROGRAMMING INSTRUCTIONS FOR THE COUNTER VERSION OF THE GEMINI

The first part of this section provides detailed description of the function
command codes for counting modes, 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 selects the unit to functionasa counter.

This is the basic personality mode and must be programmed before any
other modes areset. (This command forces defaultmode values in 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 the counter to count in the negative direction.

[43 3] TWO(2)INPUTANTI-COINCIDENCEADD/SUBTRACT-Thismode

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 pulse trainsignal shifted 90

o

away from

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 the inputshifted 90

o

away from A). For quadraturewith 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 rules providethe basis for anti-jitter operation which willprevent
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.Insteadthe logic rules for A are
complemented, allowing both edges of A to be counted. This doubles the
effective resolution of the encoded input.

[43 6] QUADRATURE TIMES4 - This modetakes the quadrature mode, with

two edge counting, one step further. In quadrature times4, both Input A and
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.

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 thatare 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 a smallscale factor could cause the internal count
value to be exceeded before the 6-digit display value is 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 decimal point,digit 1, is never turnedon.) 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

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 theOutputTime Delay. (Note: For theGemini2000, 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 held low or the front panelreset button is pressed. The second is a
“momentary” reset in which the unit resets when reset is activated and
immediately starts counting eventhoughtheterminal may still be low or the reset
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 the absence of a “-” sign will give “maintained” reset.

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

accomplished by pullingremote reset to ground, orif the front panel reset
is enabled, by pressing the front panel reset button. 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 panel reset button. Reset is “maintained”.

LEADING ZERO
BLANKING

LEADING ZERO
BLANKING INHIBITED

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] AUTOMATICRESET TO PRESET AFTER OUTPUTTIME 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 at the beginning of the output time delay(when
the preset point is reached). Forthe Gemini 2000, the output 1 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, theoutput 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 is done tohelpprevent a 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 notdeactivateuntil the moment a reset occurs.Thereset 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 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 todrop below preset, theoutput would 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.

[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 has the capabilityof varying the output time delay from 0.01 second
to 599.99 seconds. When the code is entered, instead of a single mode identifier
digit beingdisplayed, six digitswill be shown. Refer to the “ProgrammingPreset,
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 has six Output2 Termination Modes. They are: Terminate at
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 phaseoperation, when the
count reaches preset 2, output 2 will turn on. The reset condition of the output is
output off.In reverse phaseoperation,theoutput turns off when the presetis reached.
The reset condition ofthe 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 is done tohelpprevent a hazardous situation from
occurring. If other than boundary or time delay operation is selected, the unit
should be reset upon power up.

[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 notdeactivateuntil the moment a reset occurs.Thereset can be
from the front panel button or fromthe remote reset terminal, at the rear ofthe
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 todrop below preset, theoutput would 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]

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, six digitswillbe shown. 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 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 can beused. Therefore, a normal count of 1 couldbe shown as
a 10, 100, or 1000 without setting or changing any other parameter of the system.

Note: Use of dummyzeros or scale factor values greater than onecould cause the

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 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 Accessible Functions” mode selected.

A “-”sign in front of the modeidentifierwilldisable reset and 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 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.

[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 to 999,999.Refer to “ProgrammingThe Presets, ScaleFactors,
And Timed Output Values” section for instructions on entering the Preset Value.

The Scale Factor value will havea direct effect on the preset 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.

“P”(1) - PRESET 1 VALUE

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

SCALE FACTOR

“SF”(3) SCALE FACTOR- The internal count valueis 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 fromexisting 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.)

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 mustbe generated per measuring unit.For example, if 5 pulses
are being received per foot of material, the precision of 10th of feet cannot be
attained by simply programming a 2.000 scale factor, even though the display is
reading in tenths. In this case, the display will increment by two for each count
input. 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.

DUAL PRESET COUNTING & PROGRAMMING APPLICATION EXAMPLE

A typical industrial applicationfor Gemini 2000 will require both aslowdown
output and a final stop 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 typicallength of material for
this application is 10,000 feet for total length, and a slow down output 500 feet
prior to the end of the 10,000 foot length. 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) wouldremain 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.=24 pulses/ft.

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.

K=

“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 weused the multiplier as thescale 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.

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 the programmingiscompleted,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 switch1is set to theLOGIC position. This allows InputA to function as the
count input. Switch position 2 is set to SNK. (current sinking), which provides an
internal pull-upresistor to 12 VDC.Position3 is set to HI FRQ.becauseof the high
count speeds involved. Position 4 is set to HI BIAS for higher noise immunity.
Since theGemini 2000 will becountingdown, Input B willbe used as thedirection
input which will be fixed. To count down, Input B must be held low. To do this,
switch position5 can be setin the SRC. positionwhich connects a 3.9K pull-down
resistor at Input Bto COMM. The positions of switches 6 and 7are set, 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 functioncode 46 (Decimal Point & Leading Zero Blanking), and

enter a mode identifier of 1 for no decimal points with Leading Zero Blanking.

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 functioncode 52 (Output1 Termination Modes), and enter a mode

identifier of 3 (Terminate at Start of Manual Reset). Output 1 is the slow down
output which once activated should remain so until the unit is reset for start up.

STEP 8 -Enterfunction code 54 (Output 2TerminationMode), and enter a mode

identifier of-3 (Terminate atstart of ManualReset, 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 P(1) and then enter the desired slow down value (500 is used in

this application).

STEP 11 - Press P(2) and enter the total length of material to be processed

(10,000 feet).

STEP 12 - Press “SF”(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 be possible are
resetting the unit and changing the presets.

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,usingan actual application example,the programming instructions for
a rate indicator willbe “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 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] 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. This

effectively doubles the resolution

of the input signal.

CODE 45 - SCALE MULTIPLIER

There arefour scale multiplier values thatare 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 rate value.

[45 1] SCALEMULTIPLIER VALUE OF 1 -This value multiplies the internal

rate by 1.

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

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

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

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

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

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

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 decimal point,digit 1, is never turnedon.) 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 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 setting of function code 51 is
not relevant to the desired operation of the unit, and thus need not be
programmed. TheGemini is designed to automaticallyupdate at the endof every
sample time cycle, which will provide a continuous rate indication reading, as is