Red Lion GEMINI 52 User Manual

THE ASTRO LINE SERIES

GEMINI 5200 INSTRUCTION MANUAL

INTRODUCTION

The Gemini 5200 is another unit in a multi-purpose series of industrial control products 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 5200, 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 2

A) Safety Summary B) Programming The Gemini 5200 C) Programming The Personality D) Programming The Presets, Scale Factors, Timed Output Values E) Factory Settings F) Operator Accessible Functions With Programming Disabled G) Diagnostics, Self-Test, & “Watchdog” Timer H) Input Circuitry & Set-up I) Overflow Indication

II. PROGRAMMING THE GEMINI 5200 IN DUAL RATE WITHOUT DISPLAY C MODE

A) Codes 41, 42, 43, 44, 45, & 46 B) Codes 51, 52, 53, 54, 55, & 56 C) Codes 61, 62, 63, 64, 65, 66, Preset Values, & Scale FactorsA&B

III. PROGRAMMING THE A/B, (A-B)/B, & A-B DISPLAY C MODES

A) Basic Operation B) Codes 41, 42, 43, 45, & 46 C) Codes 51, 52, 53, 54, & 55 D) Codes 61, 62, 63, 64, 65, 66, Preset Values, & Scale FactorsA&B E) Gemini 5200 Programming Example - Speed Ratio Application

IV. GEMINI 5200 20 MA CURRENT LOOP COMMUNICATIONS

A) Communication Format B) Sending Commands & Data To The Gemini 5200 C) Receiving Data From The Gemini 5200 D) Print Options E) Current Loop Installation F) Communications Application G) Troubleshooting Gemini Serial Communications & Serial Loop-Back Self-Test

V. APPENDIX “A” - INSTALLATION & INPUT CONFIGURATION SWITCH SET-UP VI. APPENDIX “B” - SPECIFICATIONS & DIMENSIONS VII. APPENDIX “C” - TROUBLESHOOTING GUIDE VIII. APPENDIX “D” - DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY IX. APPENDIX “E” - GEMINI 5200 DUAL RATE W/DISP C FUNCTION COMMAND CODE SUMMARY X. APPENDIX “F” - SCALING FOR RATE & DISPLAY C XI. APPENDIX “G” - GEMINI 5200 PROGRAMMING CHARTS XII. APPENDIX “H” - ORDERING INFORMATION

3-4 5-6

9-10 10-12 12-14

15-16 16-18 18-20 21-22

24-25

30-37 38-39 40-41 42-45 46-49 50-52 53-56

2 2 2

7 7 8 8 9

15 15

23 23

26 26 27 28 29

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GENERAL DESCRIPTION

The Gemini 5200 is a multi-function dual rate indicator which can fulfill almost any rate indication application. The unit can operate as two independent rate indicators, with scaling, decimal point placement, and update times, separately programmable for each channel. TheGemini5200alsohas three other unit personalities. These modes feature a third display channel, C, which can indicate the ratio, difference or draw between the A and B rate channels.

The programming of the rate channels and the calculated display is very straightforward. Setting up Channel C only requires programming the desired amount of resolution (for ratio and draw) and the appropriate decimal point location. The Gemini 5200 simply takes the two rate values and mathematically calculates display C accordingly.

The Gemini 5200 20 mA Current Loop Communications option provides the capability of two-way serial communications between the Gemini 5200 and a variety of equipment, such as a printer, remote terminal, programmable controller, or host computer. The baud rate can be set to 300, 600, 1200, or 2400 baud. The format for transmitted and received data is 1 start bit, 7 data bits, 1 parity bit (odd), andastopbit.Whenutilizinganexternalpowersupply(30VDC max.), up to sixteen units can be installed in the loop, each with an individual address. When utilizing the Gemini’s20mAcurrentsource, up to seven unitscan be installed in a loop. The Rate Values, Presets, and Scale Factor can be interrogated or changed by sending the proper command codes and numerical data (if required) to the unit. Various “Print Options” can be selected to automatically interrogate the Rate Values, Presets, and Scale Factor by activating the “Print Request” terminal or by sending a “Transmit Per Print Option” (P) command.

The construction of the Gemini 5200 features a metal die-cast bezel, offering maximum durability with a high quality die-cast appearance. The sealed front panel meets NEMA 4/IP65 specifications for washdown and/or dust when properly installed. Clamp type pressure plate terminals accept stripped #14 AWG wire without lugs.

SAFETY SUMMARY

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

Do notusethisunittodirectly 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 5200

When your Gemini 5200 arrives from the factory, it has already been programmed to function as a Dual Rate Indicator without the calculated C display. It is programmed with the factory settings listed in the “Factory Settings” section. If it is required to have the unit operate as a speed ratio, speed difference or draw indicator, the Unit Personality function code can be changed to do so.

The personality, functions, and modes are accessed by pressing the appropriate keys as indicated by the embossed numbers above them. 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 to the left of the mode.

Data for the Presets, Scale Factors and Timed Output Values are entered differently. Each digit key controls the digit on the display directly above it. Changing the digits can be done by repeatedly pressing the key beneath the digit position you wish to changeor by holding the key down. As you hold it down,or repetitively press it, the value of that digit will change cyclically, counting up to 9, then to 0, and thenup again. The 6 numbered keys correspond to thesix digits, and the “+/-” key corresponds to polarity.

PROGRAMMING THE PERSONALITY

Entering function and mode is easily accomplished by pressing the appropriate digit key. For the personality function, you would enter 41 by pressing the front panel keys, 4 and 1.

The digitsontheleftside of the display show the function code; the digits on the right side show the current programmed mode.

A newmode selection is made by enteringanew 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.

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Pressing the “E” key finalizes the change. The display

will now show the rate value immediately.

If you do not press the “E” key, the change will not be recorded. The displaywillremainintheprogrammingmode for 15 seconds, and then return to normal operating mode using the old function and mode settings.

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

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

PROGRAMMING THE PRESETS, SCALE FACTORS & TIMED OUTPUT VALUES

The Presets and Scale Factor Values are commonly reprogrammed on a daily basis. As such, single keystroke access has been provided on the front panel.

The Gemini 5200 has two Scale Factors, one for Rate Display A,and one for Rate Display B. Pressing the “3”key will call up the Scale Factor for the current rate value being displayed (Rate A or Rate B).

To call up the “other” Scale Factor, the “+/-” key is first pushed to change the display to the “other” value (Rate A or Rate B), then the “3” key is pushed to display the Scale Factor for that value.

The internal unscaled rate valueismultipliedbythe Scale Factor Value,which

changes the displayed value accordingly.

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

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

The new valuewillbeentered when the“E”keyis pressed.

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

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

The new valuewillbeentered when the“E”keyis pressed.

To changetheTimedOutput 1 Value, enter function code 53 and enter the new value by holding down or repeatedly pressing the keybelowthedigit position youwishto change.

The newvalue willbe entered when the “E” key is pressed. The display will immediately return to the rate value.

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PROGRAMMING THE PRESETS, SCALE FACTORS & TIMED OUTPUT VALUES [Cont’d]

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

5200. Ifa value of 0 is entered into the display, and the “E”key is pressed, the unit will remain in data entry mode. If a new value is not entered, it will time out and the unit will continue to use its previous setting.

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, and the display returns to operating mode without any changes to the value. The only time any change will occur is when the “E” key is pressed.

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FACTORY SETTINGS

INITIAL FACTORY CONFIGURATION (DUAL RATE)

Keys Struck Display Description

4,1 41 1 Personality selected as DUAL RATE W/O DISP C

4,2 42 3 Reset RateA&Boutputs

4,3 43 1 Rate B Conversion Factor is Rate Per Second (x1)

4,4 44 1 Rate B Minimum Update time of 0.5 Sec.

4,5 45 4 Rate B Scale Multiplier of 1.0

4,6 46 1 Rate B leading zero blanking and no decimal point

5,1 51 1 Output 1 assigned to Rate A, Output 2 to Rate B

5,2 52 3 Output 1 terminates at Reset, Normal Phase

5,3 0000.10 Timed Output 1 value of 0.1 Sec.

5,4 54 3 Output 2 terminates at Reset, Normal Phase

5,5 0000.10 Timed Output 2 value of 0.1 Sec.

5,6 56 4 No Rate B right hand dummy zeros

6,1 61 4 No Rate A right hand dummy zeros

6,2 62 1 Rate A Conversion Factor is Rate per Second (x1)

6,3 63 1 Rate A Minimum Update Time of 0.5 Sec.

6,4 64 4 Rate A Scale Multiplier of 1

6,5 65 1 Rate A leading zero blanking, no decimal point

6,6 66 1 No functions except Reset enabled

3 01.0000 Scale Factor A (Rate A) set to 1.0000

3 01.0000 Scale Factor B (Rate B) set to 1.0000

1 000500 Preset 1 set to 500

2 001000 Preset 2 set to 1000

DUAL RATE WITH SPEED RATIO FACTORY SETTINGS *

Keys Struck Display Description

4,1 41 2 Personality selected as DUAL RATE W/SPEED RATIO

4,2 42 3 Reset RateA&Boutputs

4,3 43 1 Rate B Conversion Factor is Rate Per Second (x1)

4,5 45 4 Rate B Scale Multiplier of 1.0

4,6 46 1 Display C leading zero blanking and no decimal point

5,1 51 1 Output 1 assigned to Rate A, Output 2 to Rate B

5,2 52 3 Output 1 terminates at Reset, Normal Phase

5,3 0000.10 Timed Output 1 value of 0.1 Sec.

5,4 54 3 Output 2 terminates at Reset, Normal Phase

5,5 0000.10 Timed Output 2 value of 0.1 Sec.

6,1 61 1 Display C Multiplier of 1

6,2 62 1 Rate A Conversion Factor is Rate per Second (x1)

6,3 63 1 Rate Minimum Update Time of 0.5 Sec.

6,4 64 4 Rate A Scale Multiplier of 1

6,5 65 1 RateA&Bleading zero blanking, no decimal point

6,6 66 1 No functions except Reset enabled

3 01.0000 Scale Factor A (Rate A) set to 1.0000

3 01.0000 Scale Factor B (Rate B) set to 1.0000

1 000500 Preset 1 set to 500

2 001000 Preset 2 set to 1000

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

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FACTORY SETTINGS [Cont’d]

DUAL RATE WITH SPEED DIFF. FACTORY SETTINGS *

Keys Struck Display Description

4,1 41 3 Personality selected as DUAL RATE W/SPEED DIFF.

4,2 42 3 Reset RateA&Boutputs

4,3 43 1 Rate B Conversion Factor is Rate Per Second (x1)

4,5 45 4 Rate B Scale Multiplier of 1.0

4,6 46 1 Display C leading zero blanking and no decimal point

5,1 51 1 Output 1 assigned to Rate A, Output 2 to Rate B

5,2 52 3 Output 1 terminates at Reset, Normal Phase

5,3 0000.10 Timed Output 1 value of 0.1 Sec.

5,4 54 3 Output 2 terminates at Reset, Normal Phase

5,5 0000.10 Timed Output 2 value of 0.1 Sec.

6,2 62 1 Rate A Conversion Factor is Rate per Second (x1)

6,3 63 1 Rate Minimum Update Time of 0.5 Sec.

6,4 64 4 Rate A Scale Multiplier of 1

6,5 65 1 RateA&Bleading zero blanking, no decimal point

6,6 66 1 No functions except Reset enabled

3 01.0000 Scale Factor A (Rate A) set to 1.0000

3 01.0000 Scale Factor B (Rate B) set to 1.0000

1 000500 Preset 1 set to 500

2 001000 Preset 2 set to 1000

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

DUAL RATE WITH SPEED DRAW FACTORY SETTINGS *

Keys Struck Display Description

4,1 41 4 Personality selected as DUAL RATE W/SPEED DRAW

4,2 42 3 Reset RateA&Boutputs

4,3 43 1 Rate B Conversion Factor is Rate Per Second (x1)

4,5 45 4 Rate B Scale Multiplier of 1.0

4,6 46 1 Display C leading zero blanking and no decimal point

5,1 51 1 Output 1 assigned to Rate A, Output 2 to Rate B

5,2 52 3 Output 1 terminates at Reset, Normal Phase

5,3 0000.10 Timed Output 1 value of 0.1 Sec.

5,4 54 3 Output 2 terminates at Reset, Normal Phase

5,5 0000.10 Timed Output 2 value of 0.1 Sec.

6,1 61 1 Display C Multiplier of 1

6,2 62 1 Rate A Conversion Factor is Rate per Second (x1)

6,3 63 1 Rate Minimum Update Time of 0.5 Sec.

6,4 64 4 Rate A Scale Multiplier of 1

6,5 65 1 RateA&Bleading zero blanking, no decimal point

6,6 66 1 No functions except Reset enabled

3 01.0000 Scale Factor A (Rate A) set to 1.0000

3 01.0000 Scale Factor B (Rate B) set to 1.0000

1 000500 Preset 1 set to 500

2 001000 Preset 2 set to 1000

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

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OPERATOR ACCESSIBLE FUNCTIONS WITH PROGRAMMING DISABLED

One of the important features of the Gemini 5200 is the ability to disable programming. With this ability, accidental bumping of the keys or tampering by unauthorized personnel canbe prevented.However, itmay benecessary toallow reset and certain programming functions, such as Presets and Scale Factor Values, to be changed indaily operation. The Gemini5200, through the use ofthe “Operator Accessible Functions” modes, can enable these functions even when the “PGM. DIS.” terminal is connected to “COMMON”.

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

There are 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 RESET ENABLED - 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 entire front panel is disabled with the exceptions of Scale

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

interrogated.

All of these modes can be modified with the addition of a “-” sign. The minus sign disables the manual reset, at the front panel and the remote reset (RST., not RST.A) terminal, at the rear of the unit.

There is also a rear panel DIP switch which permits disabling of the front panel reset button. This is independentof the rear terminal remote reset, and canbe used in conjunction with any front panel disable mode. The combination of a manual and remote reset inputs provides a high level of security without sacrificing flexibility.

DIAGNOSTICS, SELF-TEST, & “WATCHDOG” TIMER

The security of the Gemini5200 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 5200. Whenever the power is turned off, all pertinent function settings and measurements are automatically saved. When power is restored, the functions and data are re-instated. This allows you to program the unit once and not have to re-program it until you wish to use it in another mode.

When the function codes and data are saved, computations are made with these values.The resultof these computations is stored in the memory to serve as a check against possible error. On powerup, the same computations are repeated on the stored data. If the results do not agree with the stored results, a “P” will appear onthe left side of thedisplay. If this occurs, refer to the “Troubleshooting Guide” for directions.

The Gemini 5200 also contains a “watchdog” timer. In order to insure the software is functioning properly, the program constantly monitors itself. If the proper sequence and timing of internal events does not occur, an “E” will appear on the left side of the display. If this occurs, refer tothe “Troubleshooting Guide” for directions.

The final type of built-in check, is the front panel initiated self-test. It can be performed at any time, even when the Gemini 5200 is running. It will not interfere with the accumulation ofcounts orcontrol functions. A function codeof “6”, “+/-” starts the test.At this time, whatever was displayed will disappear and be replaced by a string of decimal points and the overflow indicator. Then the display willshow a string of 9’s, then 8’setc., until a string of 0’s areshown. The self-test will then turn off the overflow indicator and activate the minus “-” sign. Then the unit shows an interlace pattern of -010101, then -212121, followed by

-232323 etc., until -898989 is reached. At this time the outputs can be tested by pressing the “1” or “2” key. (The program disable pin must be disconnected in order to allow activation of the outputs.) An automatic exit will take place after six seconds or immediately if the Program Disable terminal is connected to common. Normallength ofdisplay timefor eachof the patterns is approximately

0.5 sec. Rapidly pressing “E” during self-test can speed up the sequence.

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INPUT CIRCUITRY & SET-UP

There are two independent input channels on the Gemini 5200. Various types of sensoroutputs can be accommodated by appropriate DIP switch set-up.These include: TTL or CMOS logic, current sinking, current sourcing, dry contact or magnetic pickup.

Both Input Channels A and B consist of a logic input and a separate low level magnetic pickup input. For a complete detailed description of input set-up, see Appendix “A”.

OVERFLOW INDICATION

The Gemini5200 features anoverflow indicator (LED)which is locatedto the left of the sixth digit and above the polarity annunciator. This LED will turn on if the capacity of the display (6-digits) is exceeded or if the following conditions occur.

Upon power-up, the display willgo to zero, andthe overflow LED will turnon. The overflow LED is turned on to indicate that the zero on the display is not a measured value. The overflow LED will turn off after the Gemini 5200 completes its rate measurement. It will take 16 seconds if the rate is zero.

The overflow LED can also turn on when the rate input frequency exceeds the maximum 3250 cps allowed for a rate update period of 16 sec. See Code 63 “Rate Minimum Update Time”.

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PROGRAMMING THE GEMINI 5200 IN DUAL RATE WITHOUT DISPLAY C MODE

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

In the Dual Rate, without Display Cmode, thetwo rateindicators operate in an independent non-synchronized fashion. Input A serves as the inputto the Rate A indicator and Input B serves as the input to the Rate B indicator. All modes are independently selected for each rate channel.

CODE 41 - UNIT PERSONALITY

The unit personality mode is the first function code that is programmed. This mode will determine the basic operational characteristics of the unit. This programming section deals with the unit programmed as a Dual Rate Indicator without Display C, mode 1. The “Programming The A/B, (A-B)/B, And A-B Display C Modes” section covers programming of the Gemini 5200 whenin Unit Personality modes 2, 3, and 4.

Once the Unit Personality mode is changed, the factory settings will automatically be loaded into the unit’s memory. This provides a known starting place. If at any point, it is desired to return to the factory settings for the current mode, the unit personality is called up, a minus is put in front of the mode by pressing the“+/-” key, and the “E” key is pushedto load the factory settings. The factory settings are listed on page 5 and 6.

[41 1] DUAL RATE INDICATION - In this mode, the Gemini 5200 operates as

two independent rate indicators.

[41 2] DUAL RATE WITH A/B DISPLAYC-Inthis unit personality, the

Gemini 5200 operates as a dual rate indicator with an A/B display C function.

See “Programming The A/B, (A-B)/B,And A-B Display CModes” section for

programming details.

[41 3] DUAL RATE WITH A-B DISPLAYC-Inthis unit personality, the

Gemini 5200 operates as a dual rate indicator with an (A-B) Display C function. See “Programming The A/B, (A-B)/B, And A-B Display C Modes” section for programming details.

[41 4] DUAL RATE WITH (A-B)/B DISPLAYC-Inthis unit personality, the

Gemini 5200 operates as a dual rate indicator with an (A-B)/B Display C function. See “Programming The A/B, (A-B)/B, And A-B Display C Modes” section for programming details.

[41 -1] [41 -2] A minus indicator preceding the mode will cause [41 -3] the factory settings to be loaded when entered. [41 -4]

CODE 42 - RESET KEY & TERMINAL ACTUATION MODES

The Reset Button & Terminal Actuation Modes controls the effect that the reset button and terminal have on the two display channels. Resetting will not affect the rate displays or update period in any manner. Reset only affects the output(s) associated with the rate channels.

There is a separate “Rst A” terminal provided which makes it possible to independently reset both the Rate A and B Outputs.

[42 1] RESET RATE A OUTPUT(S) [42 2] RESET RATE B OUTPUT(S) [42 3] RESET RATEA&BOUTPUTS

CODE 43 - RATE B CONVERSION FACTOR

The Rate B Conversion Factor is used to convert Display B to indicate rate in the desired time unit. See Appendix “F” - Scaling For Rate And Display C.

[43 1] Rate Per Second (x1) [43 2] Rate Per Minute (x60) [43 3] Rate Per Hour (x3600)

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CODE 44 - RATE B MINIMUM/MAXIMUM UPDATE TIME

The determination of the rate value usesa method in which theelapsed time is measured between the first and last pulse of the update period. The minimum update time is the shortest the time period can be. Once the minimumupdate time has expired, the unit will end the measurement period when the next negative going count edgeoccurs. Ifthe unitdoes notreceive thenext negative count edge within the maximum update time at the start of the measurement period, the unit will end the time period and the rate display will go to zero. At very slow count rates the update time period will be the actual period of one count cycle.

[44 1] 0.5 Sec. minimum/1 Sec. maximum [44 2] 1 Sec. minimum/2 Secs. maximum [44 3] 2 Secs. minimum/4 Secs. maximum [44 4] 4 Secs. minimum/8 Secs. maximum [44 5] 8 Secs. minimum/16 Secs. maximum (max. rate = 7500 cps) [44 6] 16 Secs. minimum/32 Secs. maximum (max. rate = 3250 cps)

CODE 45 - RATE B SCALE MULTIPLIER

The Rate B Scale Multiplier is used in conjunction with the Rate Scale Factor B and Rate B Conversion Factor to scale the actual signal input to obtain the desired reading.

[45 1] x 1000 [45 2] x 100 [45 3] x10 [45 4] x1 [45 5] x 0.1 [45 6] x 0.01

CODE 46 - RATE B DECIMAL POINT & LEADING ZERO BLANKING

There are six basic modes of decimal point placementfor the Rate B indicator of the Gemini 5200. The decimal point is placed to the right of the display digit that corresponds to the mode identifier. (The right most decimal point, digit 1, is never turned on.) A “-” sign in front of the mode identifier will inhibit leading zero blanking. The absence of a “-” sign will enable leading zero blanking.

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

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

CODE 51 - OUTPUT ASSIGNMENT

The outputs of the Gemini 5200 can be assigned to either the Rate A or Rate B

channel or one to each.

The Gemini 5200 has a Preset tracking feature which allows Preset 1 to track Preset 2.If Presettracking isprogrammed, wheneverthe Preset2 valueis changed, the Preset 1 value will also change to maintain the same offset. For example, if Preset 1 is 100 and Preset 2 is 200, changing Preset 2 to 300 will automatically change Preset1 to200, maintainingthe same100 unitoffset. Inorder to change the amount of offset, the Preset 1 value is changed. The Preset tracking feature is programmed by adding a “-” modifier in front of the desired mode.

Note: When Preset tracking is enabled, before changing Preset 2 via serial

communications, the Preset 2 value must be interrogated in order to establish

the Preset 1 value.

[51 1] Output 1 assigned to Rate A, Output 2 assigned to Rate B [51 2] Outputs1&2assigned to Rate B [51 3] Outputs1&2assigned to Rate A

[51 -1] [51 -2] [51 -3]

These modes are the same as above with the exception that Preset Tracking is enabled.

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CODE 52 - OUTPUT 1 TERMINATION MODES

The Gemini 5200 has four “Output 1 termination Modes” which control the way Output 1 will terminate or reset. In all modes, Output 1 will terminate immediately when the channel to which it is assigned is manually reset.

A reverse phase mode is available on the Gemini 5200. This refers to the complementing of the logic state of Output 1. With normal phase operation, when the display value reaches Preset 1, Output 1 will turn on. The reset condition ofOutput 1 is output off. In reversephase operation, Output 1 turns off when Preset 1 is reached. The reset condition of Output 1 is output on. (Note: The state of the relay, if used, is also reversed.) A “-” sign in front of the mode identifier will provide for reverse phase operation. The absence of a “-” sign will indicate normal phase operation.

[52 3] TERMINATE AT MANUALRESET -Output 1 activates whenthe rateis

greater than or equal to the Preset 1 value. In this mode, once Output 1 is

activated, it does not deactivate until the moment a manual reset occurs.

Output 1 is set for normal phase operation.

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

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

normal phase operation.

[52 5] TERMINATE AFTER TIMED OUTPUT1-Ifboth outputs are assigned to

the same rate channel [51 2,3], Output 1 will activate when the rate is below or

equal tothe Preset 1 value. Ifeach output is assigned toa different channel [51 1],

Output 1 will activate whenthe rateis greaterthan or equal to the Preset1 Value.

Output 1 will terminate after the “Timed Output 1 Value” if the timed output

value is less than the update time of the rate channel. If the timed output value is

greater than the update time,the outputwill appear to be latched on,deactivating

when therate drops below the Preset[51 1], or above the Preset [51 2,3] andthe

output time expires. Output 1 is set for normal phase operation.

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

as the boundary point. When the rate value is less than Preset 1, Output 1 is not

activated (normal phase). When the rate value is greater than or equal to the

Preset, Output 1 is activated. If the display value were to drop below Preset 1,

Output 1 would then deactivate. Output 1 is set for normal phase operation.

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

CODE 53 - TIMED OUTPUT 1 VALUE

The Gemini 5200 has the capability of varying the Timed Output 1 value from

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

The Timed Output 1 Value is used only when in timed output termination

mode, [52 5].

Note: A Timed Output Value of zero cannot be programmed intothe Gemini 5200.

If avalue of 0 is enteredinto the display and the “E” key is pressed, the unit will not enterthe 0, but will stay in the data entrymode. Ifa new value is not entered, it will time out and the unit will continue to use its previous setting.

CODE 54 - OUTPUT 2 TERMINATION MODES

The Gemini 5200 has four “Output 2 termination Modes” which control the way Output 2 will terminate or reset. In all modes Output 2 will terminate immediately when the channel to which it is assigned is manually reset.

The reset condition of Output2 is output on. (Note:The stateof the relay, ifused, is also reversed.) A “-” sign in front of the mode identifier will provide for reverse phase operation. The absence of a “-” sign will indicate normal phase operation.

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CODE 54 - OUTPUT 2 TERMINATION MODES (Cont’d)

[54 3] TERMINATEAT MANUALRESET -Output 2activates whenthe rateis

greater than or equal to the Preset 2 value. In this mode, once Output 2 is activated, it does not deactivate until the moment a manual reset occurs. Output 2 is set for normal phase operation.

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

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

[54 5] TERMINATE AFTER TIMED OUTPUT 2 - Output 2 will activate when

the rate isgreater thanor equal to thePreset 2 Value andwill terminate after the “Timed Output 2 Value” expires. This will occur every update time period for which the above condition istrue. Ifthe output duration time isgreater thanthe update time, Output 2 will appear to be latched on, deactivating when the rate drops below the Preset and the output time expires. Output 2 is set for normal phase operation.

[54 6] BOUNDARY MODE -When in boundary mode, the Preset2 Value serves

as the boundarypoint. Whenthe ratevalue isless than Preset 2, Output 2 is not activated (normal phase). When the rate value is greater than or equal to Preset 2, Output 2 is activated. If the display value were to drop below Preset 2, Output 2 would then deactivate. Output 2 is set for normal phase operation.

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

CODE 55 - TIMED OUTPUT 2 VALUE

The Gemini 5200 has the capability of varying the timed output from 0.01 second to 599.99 seconds. When the code is entered, instead of a single mode identifier digitbeing displayed, six digits willbe shown. Refer to “Programming The Presets, Scale Factors, And Timed Output Values” section for more details about entering. TimedOutput 2will be terminated ifthe unit is manuallyreset.

The Timed Output 2 Value is used only when in timed output termination mode, [54 5].

Note: A Timed Output Value of zero cannot be programmed intothe Gemini 5200.

CODE 56 - RATE B RIGHT HAND DUMMY ZEROS

Dummy zeros can be usedto alleviatedisplay fluctuationsdue to an unstable input signal. Thesezeros effectively movesignificant digits to the left. Therefore, a normal rate display of 1 could be shown as a 10, 100, or 1000. Using the dummy zeros will make it necessary to adjust the scaling if they were not considered before.

[56 1] 1 RIGHT HAND DUMMY ZERO [56 2] 2 RIGHT HAND DUMMY ZEROS [56 3] 3 RIGHT HAND DUMMY ZEROS [56 4] NO RIGHT HAND DUMMY ZEROS

CODE 61 - RATE A RIGHT HAND DUMMY ZEROS

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

CODE 62 - RATE A CONVERSION FACTOR

The Rate A Conversion Factor is used to convert Display A to indicate rate in the desired time unit. See Appendix “F” - Scaling For Rate And Display C.

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

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CODE 63 - RATE A MINIMUM/MAXIMUM UPDATE TIME

The determination of the rate value usesa method in which theelapsed time is measured between the first and last pulse of the update period. The minimum update time is the shortest the time period can be. Once the minimumupdate time has expired, the unit will end the measurement period when the next negative going count edgeoccurs. Ifthe unitdoes notreceive thenext negative count edge within the maximum update time at the start of the measurement period, the unit will end the time period and the rate display will go to zero. At very slow count rates, the update time period will be the actual period of one count cycle.

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

CODE 64 - RATE A SCALE MULTIPLIER

The Rate A Scale Multiplier is used in conjunction with the Rate Scale Factor A and Rate A Conversion Factor to scale the actual signal input to obtain the desired reading.

[64 1] x 1000 [64 2] x 100 [64 3] x10 [64 4] x1 [64 5] x 0.1 [64 6] x 0.01

CODE 65 - RATE A DECIMAL POINT & LEADING ZERO BLANKING

There are six basic modes of decimal point placement for the Rate A indicator of the Gemini 5200. The decimal point is placed to the right of the display digit that corresponds to the mode identifier. (The right most decimal point, digit 1, is never turned on.) A “-” sign in front of the mode identifier will inhibit leading zero blanking. The absence of a “-” sign will enable leading zero blanking.

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

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

CODE 66 - “OPERATOR ACCESSIBLE FUNCTIONS” MODES

The Gemini 5200 has four basic levels of “Operator Accessible Functions”. Each of these levels can be modified to enable or disable manual reset. When the “PGM. DIS.” (program disable) terminal is connected to “COMMON”, access to all functions is disabled except for those listed below which will remain enabled. Allof thefunction codes and parameters can be interrogated, regardless of the “Operator Accessible Functions” mode selected.

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

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

disable reset DIP switch.

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

reset is enabled, but none of the programming functions can be changed. [66 2] PRESET PROGRAMMING AND RESET ENABLED - In this mode,

manual reset and the programming of the Preset Values are enabled. [66 3] SCALE FACTOR PROGRAMMING AND RESET ENABLED - In this

mode, manual reset and the programming of the Scale Factors are enabled. [66 4] SCALE FACTOR, PRESET PROGRAMMING & RESET ENABLED -

In this mode, manual reset and the programming of the ScaleFactor andPreset

Values are enabled.

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CODE 66 - “OPERATOR ACCESSIBLE FUNCTIONS” MODES (Cont’d)

[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 display value equals the Preset 1 or 2 Value, an output action will occur. This action depends on the previously programmed modes. The Preset Values may vary from -999,999 to 999,999. Refer to “Programming The Presets, Scale Factors, And Timed Output Values” section for instructions on entering the Preset Values.

“1” - PRESET 1 VALUE “2” - PRESET 2 VALUE

SCALE FACTORSA&B

“3” SCALE FACTOR - The Scale Factor, for whichever Value (Rate A or B) is currently being displayed, is accessed by pressing the “3” key. To access the Scale Factor of the “other” rate display value, the “+/-” key would be pushed (to change the display to the other value), then the “3” key would be pushed. The actual rate (in pps) is multiplied by the Scale Factor, Scale Multiplier, and Rate Conversion factor to obtain the desired display reading. The Scale Factor is used primarily for conversion from existing pulses per unit of measure to the required displayed units. This includes conversionfrom different units of measure(i.e feet to meters, etc.). The Scale Factor Values may range from 0.0001 to 5.9999. Refer to “Programming The Presets, Scale Factors, And Timed Output Values” section for instructions on entering the Scale Factor Values.

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PROGRAMMING THE A/B, (A-B)/B, AND A-B DISPLAY C MODES

This section will deal with the programmingand operationof the Gemini 5200 in the modes which includeDisplay C,[41 2,3,4]. Since all threedisplay Cmodes are very similar in operation, they will all be covered in one section.

BASIC OPERATION

In all of the display C modes, the Gemini 5200 performs a mathematical calculation using Rate channelsA&Btoobtain the Display C value.

The tworate indicators, use a time interval method (1/tau) to calculate the rate value. This method enables high resolution at all input rates. The unit counts input pulses and after a programmable minimum update time has occurred, it waits until the next count edge occurs, takes the elapsed time and number of edges, and calculates the rate value. At slower rates, averaging can be accomplished by programming the “Minimum Update Time”(0.5 sec.to 16 sec.) for the desired response.

When operatingin anyof the three modes which utilize display C, the two rate indicators will synchronize themselves in order to obtain an accurate display C reading. The Gemini 5200 will determine which channel is running at the slower rate, andit will use that channel to synchronize the other channel. This is done so that both time measurement windows are as close as possible. Because it is necessary to keep the measurement windows the same, there is only one Rate Minimum Update Time setting. The slower channel will determine the update time for the other rate channel and Display C.

If one rate input signal drops out before the update period has completed, that channel will go to zero after the maximum update time has expired. The channel will then continually time-out according to the maximum update time that was selected in Code 63, until a rate signal again appears on its input. After the first time-out, the other channel, which still has a rate signal on its input, will then begin to operate in a non-synchronous manner, updating according to the “Minimum Update Time” and its input frequency. It will not synchronize with the channel that timed-out, and has an update period of 16 seconds.

The Display C channel, however, will only update according to the maximum update time because it is calculated based on both of the rate channels. The rate channels will again synchronize when both channels have a rate signal on their inputs.

CODE 41 - UNIT PERSONALITY

The unit personality mode is the first function code that is programmed. This mode will determine the basic operational characteristics of the unit. This programming section deals with the unit personality programmed as a Dual Rate Indicator with Display C, modes 2, 3, or 4. A separate section, “Programming The Gemini 5200 In Dual Rate Without Display C Mode” goes over the programming of the Gemini 5200 when programmed in mode 1.

Whenever the Unit Personality mode is changed, the factory settings will automatically be loaded into the unit’s memory. This provides a known starting place. If at any point, it is desired to return to the factory settings for the current personality, the unit personality iscalled up, a minus isput infront of the modeby pressing the “+/-” key, and the “E” key is pushed to load the factory settings.

[41 1] DUALRATE INDICATION - In this UnitPersonality, theGemini 5200

operates as two independent rate indicators. See “Programming The Gemini

5200 In DualRate WithoutDisplay C Mode” sectionfor programming details. [41 2] DUAL RATE WITH A/B DISPLAY C - In this unit personality, the

Gemini 5200 operates as a dual rate indicator with an A/B (Speed Ratio)

Display C function.

[41 3] DUAL RATE WITH A-B DISPLAY C - In this unit personality, the

Gemini 5200 operates as a dual rate indicator with anA-B (Speed Difference)

Display C function.

[41 4] DUALRATE WITH(A-B)/B DISPLAYC - In this unit personality, the

Gemini 5200 operates as a dual rate indicator with an (A-B)/B (Speed Draw)

Display C function.

[41 -1] [41 -2] A minus indicator preceding the mode will cause [41 -3] the factory settings to be loaded when entered. [41 -4]

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CODE 42 - RESET BUTTON & TERMINAL ACTUATION MODES

The Reset Button &Terminal Actuationmodes controlthe effectthat thereset button and terminal have on the two display channels. Resetting will not affect the rate displays in any manner. Reset only affects the output(s) associated with the rate channels.

There is a separate “Rst A” terminal provided which makes it possible to independently reset both Rate A and B channels.

[42 1] RESET RATE A OUTPUT(S) [42 2] RESET RATE B OUTPUT(S) [42 3] RESET RATEA&BOUTPUT(S) [42 4] RESET DISPLAY C OUTPUT(S) [42 5] RESET DISPLAY C AND RATE A OUTPUT(S) [42 6] RESET DISPLAY C AND RATE B OUTPUT(S)

CODE 43 - RATE B CONVERSION FACTOR

The Rate B Conversion Factor is used to convert Display B to indicate rate in the desired time unit. See Appendix “F” - Scaling For Rate And Display C.

[43 1] Rate Per Second (x1) [43 2] Rate Per Minute (x60) [43 3] Rate Per Hour (x3600)

CODE 45 - RATE B SCALE MULTIPLIER

The Rate B Scale Multiplier is used in conjunction with the Rate Scale Factor B and Rate B Conversion Factor to scale the actual signal input to obtain the desired reading.

[45 1] x 1000 [45 2] x 100 [45 3] x10 [45 4] x1 [45 5] x 0.1 [45 6] x 0.01

CODE 46 - DISPLAY C DECIMAL POINT & LEADING ZERO BLANKING

There are six basic modes of decimal point placement for the Display C indicator ofthe Gemini5200. Thedecimal pointis placedto theright ofthe display digit thatcorresponds tothe modeidentifier. (Theright mostdecimal point,digit 1, is never turned on.) A “-” sign in front of the mode identifier will inhibit leading zero blanking. The absence of a “-” sign will enable leading zero blanking.

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

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

CODE 51 - OUTPUT ASSIGNMENT

The outputs of the Gemini 5200 can be assigned to the Rate A, Rate B, or the Display C channel.

The Gemini 5200 has a Preset tracking feature which allows Preset 1 to track Preset 2. If Preset tracking is programmed, whenever the Preset 2 value is changed, the Preset1 valuewill alsochange to maintain the same offset. For example, if Preset 1 is 100 and Preset 2 is 200, changing Preset 2 to 300 will automatically change Preset 1 to 200, maintaining the same 100 unit offset. In order to change the amount of offset,the Preset 1 value is changed. The Preset tracking feature is programmedby adding a “-” modifier in front of the desired mode.

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Note: When Preset tracking is enabled, before changing Preset 2 via serial

communications, the Preset 2 value must be interrogated in order to establish the Preset 1 value.

[51 1] Output 1 assigned to Rate A, Output 2 assigned to Rate B [51 2] Outputs1&2assigned to Rate B [51 3] Outputs1&2assigned to Rate A [51 4] Output 1 assigned to Rate B, Output 2 assigned to Display C [51 5] Output 1 assigned to Rate A, Output 2 assigned to Display C [51 6] Output1&2assigned to Display C

[51 -1] [51 -2] [51 -3] These modes are the same as above with the [51 -4] exception that Preset Tracking is enabled. [51 -5] [51 -6]

CODE 52 - OUTPUT 1 TERMINATION MODES

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

or display valueis greaterthan or equal tothe Preset 1 value. Inthis mode, once

Output 1 is activated, it does not deactivate until the moment a reset occurs.

Output 1 is set for normal phase operation.

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

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

normal phase operation.

[52 5] TERMINATE AFTER TIMED OUTPUT1-Ifboth outputs are assigned

to the same channel [51 2,3,6], Output 1 will activate when the rate or display value is below or equal to the Preset 1 value. If each output is assigned to a different channel [51 1,4,5], Output 1 will activate when the rate or display value is greater than or equal to the Preset 1 Value. Output 1 will terminate after the “Timed Output 1 Value” if the Timed Output Value is less than the update time of the rate or display channel. If the Timed Output 1 Value is greater than the programmed update time, Output 1 will appear to be latched on, deactivating when the rate or display value drops below the Preset [51 1,4,5], or above the Preset [51 2,3,6] and the output time expires. Output 1 is set for normal phase operation.

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

serves asthe boundary point. When the rate or display valueis less than Preset 1, Output 1 is not activated (normal phase). When the rate or display value is greater than or equal toPreset 1, Output 1 isactivated. If the display valuewere to drop below Preset 1, Output 1 would then deactivate. Output 1 is set for normal phase operation.

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

CODE 53 - TIMED OUTPUT 1 VALUE

The Gemini 5200 has the capability of varying Timed Output 1 from 0.01 second to 599.99 seconds. When the code is entered, instead of a single mode identifier digitbeing displayed, six digits willbe shown. Refer to “Programming Presets, Scale Factors, and Timed Output Values” section for more details about entering. The timed output will be terminated if the unit is manually reset.

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

Note: A Timed Output Value of zero cannot be programmed intothe Gemini 5200.

If avalue of 0 is enteredinto the display and the “E” key is pressed, the unit will

not enterthe 0, but will stay in the data entrymode. Ifa new value is not entered,

it will time out and the unit will continue to use its previous setting.

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CODE 54 - OUTPUT 2 TERMINATION MODES

The Gemini 5200 has four “Output 2 termination Modes” which control the way Output 2 will terminate or reset. In all modes, Output 2 will terminate immediately when the channel to which it is assigned to is manually reset.

A reverse phase mode is available on the Gemini 5200. This refers to the complementing of the logic state of Output 2. With normal phase operation, when the display value reaches Preset 2, Output 2 will turn on. The reset condition ofOutput 2 is output off. In reversephase operation, Output 2 turns off when Preset 2 is reached. The reset condition of Output 2 is output on. (Note: The state of the relay, if used, is also reversed.) A “-” sign in front of the mode identifier will provide for reverse phase operation. The absence of a “-” sign will indicate normal phase operation.

[54 3] TERMINATE AT MANUALRESET -Output 2 activates when therate or

display value is greater than or equal to the Preset 2 value. In this mode, once

Output 2 is activated, it does not deactivate until the moment a reset occurs.

Output 2 is set for normal phase operation.

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

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

normal phase operation.

[54 5] TERMINATE AFTER TIMED OUTPUT 2 - Output 2 will activate when

the rate or display value is greater than or equal to the Preset 2 Value and will

terminate after the “Timed Output 2 Value” expires. This will occur every

update time period for which the above condition is true. If the Output 2

duration time is greater than the display update time, the output will appear to

be latched on, deactivating when the rate or displayvalue dropsbelow Preset2

and the output time expires. Output 2 is set for normal phase operation.

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

serves asthe boundary point. When the rate or display valueis less than Preset

2, Output 2 is not activated (normal phase). When the rate or display value is

greater than or equal toPreset 2, Output 2 isactivated. If the display valuewere

to drop below Preset 2, Output 2 would then deactivate. Output 2 is set for

normal phase operation.

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

CODE 55 - TIMED OUTPUT 2 VALUE

The Gemini 5200 has the capability of varying theTimed Output2 Value from

0.01 second to 599.99 seconds. When the code is entered, instead of a single mode identifier digit being displayed, six digits will be shown. Refer to “Programming Presets, Scale Factors, and Timed Output Values” section for more details about entering. Timed Output 2 will be terminated if the unit is manually reset.

The Timed Output 2 Value is used only when in timed output termination

mode, [54 5].

Note: A Timed Output Value of zero cannot be programmed intothe Gemini 5200.

CODE 61 - DISPLAY C MULTIPLIER

The Display C Multiplier is used in the Speed Ratio [41 2] and Draw [41 4] modes to obtain the desired amount of resolution for Display C. For example; if Display C is indicating speedratio, andboth rates are the same,the ratiowould be

1. By using a Display C Multiplier of 10, 100, 1,000 or 10,000, in conjunction with the proper decimal point, the ratio could be read in tenths, hundredths, thousandths or ten thousandths respectively.

The Display C Multiplier is not available in the Speed Difference Unit Personality [41 3].

[61 1] x1 [61 2] x10 [61 3] x100 [61 4] x1,000 [61 5] x10,000

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CODE 62 - RATE A CONVERSION FACTOR

The Rate A Conversion Factor is used to convert Display A to indicate rate in

the desired time unit. See Appendix “F” - Scaling For Rate And Display C.

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

[64 1] x 1000 [64 2] x 100 [64 3] x10 [64 4] x1 [64 5] x 0.1 [64 6] x 0.01

CODE 63 - RATE MINIMUM/MAXIMUM UPDATE TIME

The determination of the rate value usesa method in which theelapsed time is measured between the first and last pulse of the update period. In the Display C modes [41 2,3,4], the rate channels are synchronized. The slower of the two channels will determine the minimum update time. The minimum update time is the shortest the time period can be. Once the minimum update time has expired, the unit will end the measurement period, for the synchronizing channel, when the next negative going count edge occurs. If the unit does not receive the next negative count edge within the maximum update time at the start of the measurement period, the unit willend thetime period and calculate the rate based upon the amount of pulses received during the time period. After the synchronizing channel ends its measurement period, the other channel will end its measurement period when it receives the next negative going edge.

CODE 64 - RATE A SCALE MULTIPLIER

The Rate A Scale Multiplier is used in conjunction with the Rate Scale Factor A and Rate A Conversion Factor to scale the actual signal input to obtain the desired reading.

CODE 65 - RATEA&BDECIMAL POINT & LEADING ZERO BLANKING

There are six basic modes of decimal point placement for the RateA&B indicators of the Gemini 5200. The decimal point is placed to the right of the display digit that corresponds tothe modeidentifier. (The right most decimal point, digit 1, is never turned on.) A “-” sign in front of the mode identifier will inhibit leading zero blanking. The absenceof a “-” sign willenable leadingzero blanking.

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

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

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CODE 66 - “OPERATOR ACCESSIBLE FUNCTIONS” MODES

The Gemini 5200 has four basic levels of “Operator Accessible Functions”. Each of these levels can be modified to enable or disable manual reset. When the “PGM. DIS.” (Program Disable) terminal is connected to “COMMON”, access to all functions is disabled, except for those listed below, which will remain enabled. Allof thefunction codes and parameters can be interrogated, regardless of the “Operator Accessible Functions” mode selected.

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

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

disable reset DIP switch.

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

reset is enabled, but none of the programming functions can be changed. [66 2] PRESET PROGRAMMING AND RESET ENABLED - In this mode,

manual reset and the programming of the Preset Values are enabled. [66 3] SCALE FACTOR PROGRAMMING AND RESET ENABLED - In this

mode, manual reset and the programming of the Scale Factor Values are

enabled. [66 4] SCALE FACTOR, PRESET PROGRAMMING AND RESET

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

Factors 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 rate or display value equals the PresetValue, anoutput actionwill occur. This action depends on the previously programmed modes. The Preset Value may vary from -999,999 to 999,999. Refer to “Programming the Presets, Scale Factors, And Timed Output Values” section for entering instructions.

SCALE FACTORSA&B

The Scale Factor, for whichever Value (Rate A or B) is currently being displayed, is accessed by pressing the “3” key. To access the Scale Factor of the “other” display value, the “+/-” key wouldbe pushed (to change the display to the other value),then the“3” keywould be pushed. If the “3” key is pushed while the Display C value is on the display, a scale factor will not be displayed, since the Display C value does not have a scale factor associated with it.

The actual rate (in pps) is multiplied by the appropriate Scale Factor, Scale Multiplier, andRate Conversionfactor to obtain the desired display reading. The Scale Factor is used primarily for conversion from existing pulses per unit of measure to the required displayed units. This includes conversion from different units of measure (i.efeet tometers, etc.).The ScaleFactor Valuemay rangefrom

0.0001 to 5.9999. Refer to “Programming the Presets, Scale Factors,And Timed Output Values” section for entering instructions.

“3” - SCALE FACTOR

“1” - PRESET 1 VALUE “2” - PRESET 2 VALUE

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GEMINI 5200 PROGRAMMING EXAMPLE - SPEED RATIO

A paper towel manufacturer needs to maintain a tight control on the speed relationship of two rollers. Two outputs are needed to signal when the speed relationship of the rolls are out of the operating “safe zone”. A 72 tooth gear is mounted oneach of the rolls. Two LMPC’s areused to sense the gear teeth. Each of the rolls have a circumference of 2 feet.

The Gemini 5200 can fulfill all the requirements of the system. The Gemini 5200 can provide an indication of the speed relationship, and can also provide a Feet per Minute indication of the speed at which each of the rolls are running.

The system can be set-up so that the speed relationship is given asa speedratio or draw. After programming, only the Presets will have to be changed. In this programming example, Display C will be set-up to indicate speed ratio, A/B.

SCALING THE RATE CHANNELS

Since both of the rolls have the same circumference and have gears with the same number of teeth, the scaling parameters obtained will apply to both Rate channelsA&B.

The unit of display for the rate channels will be in feet. From the information given, 72 pulses will beprovided for2 “Display Units” (feet)of linearweb travel. Utilizing the formulas and procedure in Appendix “F”, we obtain the Total Scaling Factor required, “K

To provide maximum conversion accuracy, a Scale Multiplier value of 0.01 is chosen to give the largestnumber ofsignificant digitspossible for the Scale Factor.

The Rate A & Rate B Scale Factors will be programmed for 2.7778 and the corresponding Scale Multipliers will be programmed for 0.01.

The final scaling parameter that needs to be selected is the “Rate Conversion Factors” for both of the Rate channels. To achieve rate in Feet Per Minute, the “Rate Conversion Factor”, Rate Per Minute is selected.

”.

= Display Units/Number of Pulses

= 2/72 = 0.0277777

SF=K

/SCM

SF = 0.027777/0.01 = 2.7778

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SCALING DISPLAY C

Scaling Display C is simply a matter of choosing the amount of decimal point resolution that is desired for the application. This is accomplished by selecting a Display C Multiplier and by programming the desired “Display C Decimal Point” location. To obtain Display C resolution in thousandths, a “Display C Multiplier” of 1000 is used. For example; If both rolls are operating at the same speed, the ratio would be 1. Selecting a “Display C Multiplier” of 1000 and a decimal point tothe rightof digit 4, willresult in a DisplayC readout of 1.000.

HARDWARE SET-UP

The application drawing shows how the hardware for the system is configured. The Input to both rate channels will be LMPC open collector Logic Magnetic Pickups. TheA&BInput channels will therefore, be set-up identically. The dip switch settings for various types of sensors are shown in Appendix “A”. The “EN/DIS RST.” DIP switch position, is set to the “DIS.” position to disable the use of the front panel reset button. The solid state open collector outputsof the Gemini, “O1-SNK” and “O2-SNK”, are connected to the speed control circuitry of the system.

STEP BY STEP PROGRAMMING PROCEDURE

STEP 1 - Select function code 41(Unit Personality). Select and enter mode 2 for

a Dual rate with speed ratio unit personality.

Note: Function code 42, “Reset Button & Terminal Actuation Modes” is not

programmed, since the application doesnot requirethe resettingof the outputs.

STEP 2 - Enter function code 43 (Rate B Conversion Factor). Select and enter

mode 2 for Rate Per Minute. STEP 3 - Enter function code 45 (Rate B Scale Multiplier). Select and enter

mode 6 for a Scale Multiplier of 0.01, as determined when scaling the rate. STEP 4 - Enter function code 46 (Display C Decimal Point & Leading Zero

Blanking). Select and enter mode 4 for decimal to the right of digit 4. STEP 5 - Enter function code 51 (Output Assignment). Select and enter mode 6

to assign both outputs to Display C. STEP 6 - Enter function code 52 (Output 1 Termination Mode). Select and enter

mode 6 for boundary operation.

Note: Since Output 1 is not being used in timed output operation, function code 53, the “Timed Output 1 Value”, is not programmed.

STEP 7 - Enter function code 54(Output 2Termination Modes). Select and enter

mode 6 for boundary operation.

Note: Since Output 2 is not being used in timed output operation, function code 55, the “Timed Output 2 Value”, is not programmed.

STEP 8- Enterfunction code 61 (Display C Multiplier). Select and enter mode4

for a multiplier of 1000.

STEP 9 - Enter function code 62 (Rate A Conversion Factor). Select and enter

mode 2 for Rate Per Minute.

STEP 10 - Enter function code 63 (Rate Minimum Sample Time). Select and

enter mode 1 for 0.5 second minimum sample time.

STEP 11 - Enter function code 64 (Rate A Scale Multiplier). Select and enter

mode 6 for a Scale Multiplier of 0.01, as determined when scaling the rate.

STEP 12 - Enter functioncode 65 (DisplayA&BDecimal Point &Leading Zero

Blanking). Select and enter mode 1 for no decimal point.

STEP 13 - Enter code 66 (Operator Accessible Functions Modes). Select and

enter mode (-)1 for no functions enabled. When the “PGM.DIS.” terminal is connected to “COMM.”, all programming changes will be inhibited.

STEP 14 - The “+/-” key is pushed, if necessary, so that Rate A is being indicated

on the Gemini 5200. The “3” key is then pushed to call up the Rate A Scale Factor. The value is changed to 2.7778.

STEP 15 - The “+/-” key is pushed so that Rate B is being indicated on the

Gemini 5200. The “3” key is then pushed to call up the Rate B Scale Factor. The value is changed to 2.7778.

STEP 16 - Both presets are programmed to the desired ratio limits for within

which the machine is to operate.

After the Gemini 5200 has been programmed, the “PGM. DIS.” terminal is connected to “COMM.” to prevent any unauthorized or accidental mode changes. The function codes can, however, be recalled to view or verify that the proper modes are entered.

-22-

GEMINI 5200 20 MA CURRENT LOOP COMMUNICATIONS

The Gemini 5200’s 20 mA Current Loop Communications Option allows a “two-way” serial communications link to be established in order to monitor the display values, Presets and Scale Factors from a remote location. Some typical devices that can be connected with the Gemini 5200 are: a printer, terminal, programmable controller, or host computer. For devices that use RS232, a GCM232 Serial Converter Module is available to convert the 20 mA Current Loop signals to RS232 and vice-versa.

There are two loops that must be established. One for sending commands to the Gemini5200 and one for receiving the data values from the Gemini5200. Up to sixteen Geminis or other RLC units with 20 mA serial communication capability, canbe connected together in the “loop”. These units are assigned unit addresses by setting the SerialDip Switches on each unit.The applicationscan be as simple as attaching a printer to obtain hard copy of the display information or as involved as using a host computer to automatically set up Presets and Scale Factors of a number of Geminis.

With the CommunicationsOption, thefollowing functions can beperformed:

1. Interrogation of the rate or display values, Presets, and Scale Factors.

2. Changing of the Presets and Scale Factors.

3. Resetting of the Outputs.

4. Automatic print-out when using a printer and the “Print Request” Terminal.

5. Change viewed display channel

COMMUNICATION FORMAT

Data is sent by switchingoff andon the current inthe 20mA current loop. Data is receivedby monitoring the switching action and interpreting 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 5200 will accept is: 1 start bit, 7 data bits, 1 odd parity bit, and 1 stop bit. The Baud Rates that 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]

-23-

SENDING COMMANDS & DATA TO THE GEMINI 5200

When sending commands to the Gemini 5200, a command string must be constructed. The command string may consist of command codes, value identifiers, andnumerical data.Below isa list of commands and value identifiers that are used when communicating with the Gemini 5200

COMMAND DESCRIPTION

N (4EH) Address command; followed by a unit address number 1-15

and one of the following commands.

P (50H) Transmit per Print Options command.

R (52H) Reset command; operates on Output(s) assigned to

the channel being reset.

T (54H) Transmit Value command; operates on display values,

Presets and Scale Factors.

V (56H) Change Value command; operates on Scale Factors,

and Presets.

D (44H) ChangeDisplay command;operates on display values(E -G).

VALUE IDENTIFIER DESCRIPTION MNEMONIC

A (41H) Preset 1 (PS1)

B (42H) Preset 2 (PS2)

C (43H) Scale Factor A (SFA)

D (44H) Scale Factor B (SFB)

E (45H) Rate A (CTA)

F (46H) Rate B (CTB)

G (47H) Display C (CTC)

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

5200. The Gemini 5200 will accept the decimal points, however, it does not interpret them in any way. Leading zeroscan be eliminated, however, alltrailing zeros must be present. For example, if a Scale Factor of 1.0000 is to be sent, the data value can be transmitted as 1.0000or 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 isconstructed ina specificlogical sequence. The Gemini 5200 willnot accept command strings that do notfollow this sequence. Only one operation can be performed per command string. Below is the procedure to be used when constructing a command string.

1. If the Gemini 5200, to whichthe commandis to be sent, is assigned an address

other than zero, the firsttwo characters of the command string must consist of

the Address 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 5200 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 is 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 5200 with address of 2 to 00123.4.

COMMAND STRING: N2VA1234

(EX. 2) Have the Gemini 5200, with address of 3, transmit the Rate B value.

COMMAND STRING: N3TF

(EX. 3) Reset the Rate B outputs of the Gemini 5200 with address of 0.

COMMAND STRING: RF

-24-

SENDING COMMANDS & DATA TO THE GEM52 [Cont’d]

As shown, all commands must be terminated with a “Command Terminator” (*or 2AH). The Gemini 5200 will not process the command until the terminator is sent. If illegal commands or characters are sent to the Gemini 5200, 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 and line feed should be inhibited by using the semicolon delimiter with the Print statement. TheGemini 5200 will not accept acarriage return or line feed as valid characters. See “Terminal Emulation Program” section for a listing of a terminal emulation program written in Basic.

When a “Change Value” command is sent to the Gemini 5200, 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 5200. This may be done 80 msec after the transmission of the “Change Value” command. After the second command has 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.

Note: When Preset tracking is enabled, before changing Preset 2 via serial

communications, the Preset 2 value must be interrogated in order to establish

the Preset 1 value.

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 5200 to process the preset. It varies with the Count Rate and Scale Factor Value.

FIG. 3: RESET COMMAND TIMING

-25-

RECEIVING DATA FROM THE GEMINI 5200

Data is transmitted from the Gemini 5200 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 5200 can transmit 7 values: display channel A, B and C, Presets 1 and 2, and Scale Factors A and B. A list of the abbreviations used whenthe Gemini5200 transmits the valuesare shown below.

CTA - Rate Display A Value

CTB - Rate Display B Value

CTC - Display C Value

PS1 - Preset 1

PS2 - Preset 2

SFA - Scale Factor A

SFB - Scale Factor B

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

The first two digits transmitted are the unit address followed by two blank spaces. Ifthe unitaddress is0, thefirst locations will be left blank. The next three letters arethe abbreviation for the mnemonic value followedby 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 display values are shown by an asterisk preceding the most significant digit 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 attachedto theend of the above character string.

An example of a typical serial transmission:

3 CTB 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 inthe down position, the unit will not transmit the characters before the data value (address, Value ID, spaces) or the 400 msec printer delay. The same above value when transmitted with the “PR.ID” switch in the down position, is transmitted as:

1234.56 < CR> < LF>

Note: When using the Gemini with a printer, with the “Print ID” switch in the down

position, some printers may notwork, sincethe printerdelay is not transmitted.

PRINT OPTIONS

The various Print Options areused mainly in conjunctionwith a printer and the Print Request Terminal. They provide a choice of Gemini 5200 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 5200. The various Print Options available are:

A. Print Rate Display A B. Print Rate Display B C. Print Display C D. Print Display A, B, & C E. Print Display C, Presets1&2,andScale FactorsA&B F. Print Display B, Presets1&2,andScale FactorsA&B G. Print Display A, Presets1&2,andScale FactorsA&B H. Print Display A, B, & C, Presets1&2,andScale FactorsA&B

A typical print-out is shown below. The Print Options are selected by setting S3, S4 and S5 on the Serial DIP Switch. See “Current Loop Installation” section for the various switch settings.

1 CTA 000054 1 PS1 000100 1 PS2 000200 1 SFA 01.0000 1 SFB 02.5000

-26-

CURRENT LOOP INSTALLATION

WIRING CONNECTIONS

When wiring the 20 mA current loop, remove the 7-position terminal block (TBD), located on the rightside ofthe topboard. Referto thenumbers listedwith 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 (COMM.) - Common for 20 mA SRC and Print Request

terminal.

2. PRINT REQUEST - The Print Request Terminal is pulled low to request the

Gemini 5200 to transmit according to the Print Options mode that has been

selected. (Minimum Activation time = 25 msec.)

3. +20 mA SRC - The 20mA SRC terminal provides the sourcecurrent forone of

the loops.

4. SO- (Serial Out-)

5. SO+ (Serial Out+)

The Gemini 5200 transmits the requested data on these terminals. 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 5200 receives commands on these terminals. 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 forthe Gemini5200 to respond toa Print Request terminalactivation.

SERIAL DIP SWITCH SET-UP

The SerialDIP switchesare accessible through the side of the Gemini 5200. A list of the DIP switch positions and their functions are shown in Figure 4. BR0 & BR1, BAUD RATE - Set-up is shown in Figure 4. When changing the

Baud Rate, the unit should be powered-down and then powered back up again.

The unit will only recognize a baud rate 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

Gemini will see the charactersas erroneous and it willcheck 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 5200

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 Request terminal is used. This switch position is generally used when the unit is connected with a printer. When the switch is in the down position, the Gemini 5200 will transmit only the data value, without the unit address and data ID. The 400 msec delay, described above, willnot be inserted. This switch position usageis intended for applications where the Gemini is communicating with a computer. In these circumstances printing the address and value ID and inserting a 400 msec print delay is usually unnecessary and needlessly slows down communication throughput.

PC0, PC1, & PC2, PRINT OPTIONS - Used to control which values are

printed out when the Print Request terminal is activated or when the Transmit per Print Options command “P” is sent to the Gemini 5200.

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

each unit a separate address when more than one unit is connected in the Loop. See Figure 4, for Switch Set-up.

FIG. 4: DIP SWITCH SET-UP

-27-

COMMUNICATIONS APPLICATION

PROCESS MONITORING SYSTEM

Five Gemini5200s with20 mACurrent LoopOption, areused to monitor the speed and draw of various rollers in a printing facility. The units are located near the printing presses in the production area of the building. The communications lines are run to an Industrial computer located in 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 5200 is given an address and the Serial DIP switches are set accordingly. A Baud Rate of 1200 is selected and set in each of the Gemini 5200s. An application program is written, which sends and retrieves data from the units using the Change and Transmit Value commands.

-28-

TROUBLESHOOTING GEMINI SERIAL COMMUNICATIONS

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

printer to communicate, the followingchecklist canbe usedto help find the solution.

1. Checkall wiring.Refer tothe previous application examples and use them as a guide to check your serial communication wiring. Proper polarity of all Geminis and other peripherals mustbe observed.If a multimeter or ammeteris available, insert it in series 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 Inputor Output,the unitmay havebeen damaged.If aGemini 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-up with 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 and make sure all devices in theloop 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 the Gemini, theGemini’s address 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 commandterminator (*) can be sent before the string to eliminate any illegally transmitted characters.

SERIAL LOOP-BACK SELF-TEST

The Gemini 5200 has a Serial Loop-back Self-test feature. This test enables the user toverify theoperation ofthe Geminiwhen problemsare encountered trying to get theGemini and “Host device” communicating. In thistest, 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 Gemini 5200 will change its Scale Factor B value to 0.1111. To perform 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’s unit address to 15 (set switches 7-10 of the Serial DIP Switch

to the down position).

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

test. Tocheck the results: Call up the Scale Factor B valueby pressing the “3”

key while the Rate B value is being displayed. If the Serial loop is functioning

properly the Scale Factor B value will be 0.1111. If this result is not obtained,

double check the connections with those shown in the diagram, and the unit

address switch positions and repeat step 3.

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

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

B value will change back to its previous setting.

If the unit does notpass thistest, contactyour local Red Lion Controls distributor.

-29-

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

Before installing the Gemini 5200 into the panel,the user should first become familiar with the unit. It may also be desirable to program the unit for the application at hand (Refer to the “Programming and Applications” sections). Once the unitis programmed,the settingswill besaved inmemory. TheProgram Disable “PGM. DIS.” terminal should be connected to “COMM.” to prevent accidental or unauthorized programming changes.

PANEL MOUNTING {Note: See Appendix “B” for Dimensions}

Installation Environment

The GEM5200 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 be cleaned only with a soft cloth and neutral soap product. Do NOTuse solvents. Continuous exposure to direct sunlight may acceleratethe aging process of the bezel.

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

The Gemini 5200 is intendedto be mounted intoan enclosed panel with a gasket to provide a water-tight seal. The unit meets NEMA 4/IP65 requirements forindoor use when properly installed. Two mounting clips and screws are provided for easy installation. Consideration should be given to the thickness of the panel. A panel which is too thin may distort and not provide a 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 apply the gasket to the panel. DO NOT GASKET TO THE COUNTER BEZEL. Insert the unit into the panel. Install the screws into the narrow ends of the mounting clips as shown in the drawing to the left. Thread the screws into the clips until the pointed end just protrudes through the other side.

Install each of the two mounting clips by inserting the wide lip of the clips into the wide end of the holes located on either side of the case. Tighten the screws evenly, applying uniform compression, thus providing a water-tight seal.

Caution: Onlyminimum pressureis

required to seal panel. Do NOT

over tighten mounting screws.

APPLY THE ADHESIVE SIDE OF THE

-30-

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 unitmay occur if the ACselector switchis 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 Control inputswith shielddrain wire

connected to earth ground at the mounting panel only. Belden #8451 2conductor, #22AWG twisted pair withfoil shield and drainwire Belden #8771 3 conductor, #22 AWG with foil shield and drain wire Alpha #2404 4 conductor, #22 AWG with foil shield and drain wire

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 EN61000-4-2.

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

optional DC power supply. Test: EFT Immunity per EN61000-4-4.

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.

-31-

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 bemounted in 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 surethe metal bezel makes proper contact tothe 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, conductors feeding motors, solenoids, SCR controls, 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 very electrically noisy environments, the use of external EMI suppression

devices, such as ferrite suppressioncores, is effective. Install themon Signaland

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 conform to appropriate standards of good installation, local codes and regulations. It is recommended that power supplied to the unit (AC orDC) be protected by a fuse or circuit breaker. All wiring connections are made on removable plug-in terminal blocks. There is a separate terminal block for the bottom board (TBA), relay board (TBB), rate inputs (TBC), and optional Serial Communications (TBD). When wiring the unit, remove the terminal block and use the numbers on the label to identify the position number with the proper function. Simply strip the wire, leaving approximately 1/4" bare wire exposed (stranded wires should be tinned with solder). Insert the wire into the terminal and tighten down the screw until the wire is clamped intightly. Eachterminal can accept up to two 18-gage wires. After the terminal block is wired, install it in the proper location on the PC board. Wire each terminal block in this manner.

-32-

PRIMARY A.C. WIRING

For bestresults, the A.C. primary power should berelatively “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 ACpower isconnected tothe bottomleft terminals TBA 1 & 2, marked as AC Power, 50/60 Hz. The voltage selectorswitch, located on the sideof the unit, is used to select the proper voltage. The switch is a slide movement type and can be set by using a small screwdriver. If the switch is towards thefront ofthe unit,it is set for 230 VAC input. The switch is in the 230 VAC position when shipped from the factory.

Note: Beforeapplying power to the unit, make sure the AC power selectorswitch

is set for the proper voltage setting.

USING AN EXTERNAL DC POWER SOURCE

The Gemini 5200 can be operated from a D.C. power source that provides 11-14 VDC at the unit’s rated power consumption (700 mA). The power source can bea 12 V battery or an external powersupply that is capable of supplying the unit’s rated current. It is not necessary to provide battery backup to retain programming information. The Gemini 5200 has an internal non-volatile memory in which the programming information is stored upon power-down. Refer to the “Block Diagram” section.

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: Snubberleakage current can cause some electro-mechanical devices to be

held ON.

SERIAL COMMUNICATIONS

The Gemini 5200 can be purchased with a 20 mA Current Loop Communications Option. On these units, refer to the “Current Loop Communications” section of the manual for wiring and operational procedures of the Serial Loop.

INPUTSA&BANDMAGNETIC PICKUP INPUTSA&B

The Gemini 5200 has two input channels. Input Channel A is associated with Rate Display A and Channel B is associated with the Rate Display B. The Magnetic Pickup Input and theLogic Inputof each channel utilize somecommon circuitry. For this reason the Input switches are used to set up both the Magnetic and Logic Input.

S1 selects between Magnetic Pickup Input A and Logic Input A. S5 selects between Magnetic Pickup Input B and Logic Input B. WHEN MAGNETIC PICKUP A IS BEING USED, S2 MUST BE IN THE “SNK” POSITION or the unit will not display the rate properly. Likewise, WHEN MAGNETIC PICKUP B IS BEING USED, S6 MUST ALSO BE IN THE “SNK” POSITION.

S3 (HI/LO FRQ) and S4 (HI/LO BIAS) or S7 (HI/LO FRQ) and S8 (HI/LO BIAS) do not effect the Magnetic Pickup InputsA&Bandtheir settings are inconsequential. When S1 or S5 is in the Logic position, the Magnetic Pickup Input A or B is disabled and Inputs A or B can be used as logic inputs.

Note: A Magnetic Pickup type sensor should not be used unless a large enough

signal is provided at all speeds of operation.

-33-

BLOCK DIAGRAM

-34-

CONNECTIONS & CONFIGURATION SWITCH SET-UPS FOR VARIOUS SENSOR OUTPUTS (See Note 5)

-35-

Notes:

1. SENSOR VOLTAGE AND CURRENT The +12 V sensor supply voltage on the “DC OUT” terminal is nominal with +/-25% variation due to line and internal load variations. All RLC sensors will accommodate this variation.

2. HI/LO FRQ SELECTION The HI/LO FRQ selection switch must be set on “LO FRQ” when switch contacts are used to generate rate input signals. Since the “LO FRQ” mode also provides very high immunity against electrical noise pickup, it is recommended that this mode alsobe used, whenever possible, with electronic sensor outputs. The “LO FRQ” mode can be used with any type of sensor output, provided pulse widths never decrease below 5 msec, and the 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. 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.

INSTALLATION & REMOVAL OF THE RELAY BOARD

To install the relay board, locate the relay opening at the lower right-hand corner, onthe backof theGemini 5200. 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 enough to allow the relay board to slide out. Grasp the six terminal connector and pull to remove the board.

-36-

SENSOR INPUT CONNECTIONS & INPUT CONFIGURATION SWITCH SET-UP

The accompanying diagram shows the details of the logic and magnetic pickup circuitry. The four switches used to set up Logic Input A and Magnetic Pickup A are designated S1, S2, S3, and S4. The four switches used to set up Logic Input B and Magnetic Pickup B are designated S5, S6, S7, and S8. 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 OPERATION.

S2 -SNK: Provides a 7.8 K pull-up resistor for sensorswith current sinking

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

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

max. count frequency. Min. count ON or OFF time - 50 usec. LO FRQ: Connects damping capacitor for switch contact debounce. Limits count speed to 100cps max. Min. count pulseON or OFF time 5 msec. (See Note 2.)

S4 - HI BIAS: Sets input trigger levels at mid-range to accept outputs from

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 0to 5V swings. (V

S5 - Same as S1, for Magnetic pickup B and Logic Input B. S6 - Same as S2, for Magnetic pickup B and Logic Input B. S7 - Same as S3, for Logic Input B.

CHAN. B CHANNEL A

S8 - Same as S4, for Logic Input B. S9 - DIS. RST.: Disables front panel Reset button, “R”.

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

S10 - Not used.

= 5.5 V, VIH= 7.5 V, See Note 3.)

= 1.5 V,VIH= 3.75 V,See Note3.)

Note: The circuitry for Channel B (Input B and Mag. Pkup.) is identical to that shown for A.

-37-

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 max.

3. SENSOR POWER: +12 VDC (±25%) @ 100 mA.

4. MEMORY: Non-volatile E

PROM memory retains all programming

information when power is removed or interrupted.

Power Cycles (ON/OFF): 100,000 min.

Data Retention: 10 yrs. min.

5. INPUTS A AND B: Switch selectable to accept pulses from a variety of

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

all standard RLC sensors.

Current Sourcing - Unit provides 3.9 K pull-down resistor for sensor with

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

Current Sinking - Unit provides 7.8 K pull-up resistor for sensors with

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

Debounce -Damping capacitor provided for switch contact debounce.Limits

rate to 100 Hz max. and input pulse widths to 5 msec. min.

Lo Bias - Input trigger levels V

Hi Bias - Input trigger levels V

DIMENSIONS In Inches (mm)

= 1.5 V, VIH= 3.75 V

= 5.5 V, VIH= 7.5 V

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

Note: Bias levels given are ±10% @ 12 VDC. They vary proportionally with sensor supply voltage at “DC OUT” terminal.

6. MAGNETIC PICKUP INPUTSA&B: Sensitivity: 150 mV peak (typical @ 12 VDC) Hysteresis: 100 mV Input impedance: 26.5 KW @60Hz Maximum Input Voltage: ±50 Vp

7. RATE ACCURACY AND REPEATABILITY: +0.025%

8. RATE MINIMUM INPUT FREQUENCY: 0.03 Hz

Note: At frequencies below 0.03 Hz (1 pulse every 32 sec.) the rate indicator will display a zero.

9. RATE MAXIMUM INPUT FREQUENCY: 10 KHz

10. CONTROL INPUTS: Reset - Active low (V 3 mA), Activation & De-activation response time = 10 msec. Program Disable - Active low (V VDC (I Print Request - (GEM521xx only) Active low, (V

SNK

= 1 mA).

pulled up to +5 VDC (I

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

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

= 1.5 V max.), internally

SNK

= 1 mA).

SNK

-38-

11. SERIAL COMMUNICATIONS: Type - Bi-directional 20 mAcurrent 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. (Actual number in a single loop is limited by

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

Serial Hardware Specifications -

SO - Output Transistor Rating: V SI - Input Diode Rating: V

Note: The compliancevoltage ratingof the source mustbe greater than the

max

= 1.25 V

= 30 VDC, V

; 1.5 Vmax

TYP

SAT

=1V

max

at 20 mA

sum of the voltage drops around the loop.

12. OUTPUTS: Solid-State - Current sinking NPN open collector transistors. I

maximum @ V protection).

=1V.VOH= 30 VDC max. (Internal Zener diode

SNK

= 100 mA

Relays - Mounted on a field replaceable PC board. Form C contacts rated at 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.).

13. ENVIRONMENTAL CONDITIONS:

Operating Temperature: 0 to 50°C Storage Temperature: -40 to 70°C Operating and Storage Humidity: 85% max. relative humidity

(non-condensing) from 0°C to 50°C. Altitude: Up to 2000 meters

14. 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), IEC529 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 of unit connected with ground lead from rear bezel screw to metal 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.

15. CONSTRUCTION: Metal die-cast bezel, plastic case. This unit is rated for NEMA 4/IP65 indoor use. Installation Category II, Pollution Degree 2

16. WEIGHT: 2.1 lbs (0.9 kg)

-39-

APPENDIX “C” - TROUBLESHOOTING GUIDE

The majority of difficulties arising with the Gemini 5200 are related to incorrect hook-up and programming set-up. Always check all connections, function codes, Scale Factor, and presets as a first step in troubleshooting.

Before applying power, double check all wiring. Improper AC voltage or AC connections may result in permanent damage to the unit.

For further technical assistance, contact technical support at the appropriate company numbers listed on the back cover of this 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.

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

NO RATE INDICATION 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.

Functions" modes.

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

3. Scale factor/multiplier too small. 3. Check scale factor value and scale multiplier values.

4. Input frequency below 0.03 cps. 4. At frequency under 0.03 cps (1 pulse every 32 sec) the display will read zero.

-40-

APPENDIX “C” - TROUBLESHOOTING GUIDE

PROBLEM POSSIBLE CAUSE REMEDIES

INCORRECT RATE READING 1. Input type incorrectly selected. 1. Check rear panel DIP switches. Turn on LO.

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

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

4. Incorrect scaling. 4. Review scaling parameters (Appendix “F”).

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

2. Reset disabled. 2. Check function code 42 or 66.

DATA VALUES AND FUNCTIONS WILL 1. Front panel locked out. 1. Consult manual on “Operator Accessible NOT CHANGE OR NOT RECORDED Functions” mode (66)

2. Incorrect programming procedure (“E” not pressed). 2. Consult section on programming functions in

-41-

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

sources.

sequential order.

APPENDIX “D” - GEMINI 5200 DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY

CODE MODE DESCRIPTION COMMENTS

41 UNIT PERSONALITY (-)Loads factory set code values*

42 RESET BUTTON & TERMINAL ACTUATION MODES

43 RATE B CONVERSION FACTOR

44 RATE B MINIMUM UPDATE TIME

45 RATE B SCALE MULTIPLIER

46 RATE B DECIMAL POINT & LEAD ZERO BLANKING

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

+/-1 Dual Rate W/O Display C Rate AÞDisplay A, Rate BÞDisplay B +/-2 Dual Rate W/ Ratio (A/B) See Appendix “E” for a Function Command Code +/-3 Dual Rate W/ Difference (A-B) Summary when in these modes +/-4 Dual Rate W/ Draw [(A-B)/B]

1 Reset Rate A Output(s) Reset only affects the output(s) and does not 2 Reset Rate B Output(s) change the rate display. 3 Reset RateA&BOutputs

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

1 0.5 sec minimum/1 sec maximum 2 1 sec minimum/2 sec maximum 3 2 sec minimum/4 sec maximum 4 4 sec minimum/8 sec maximum 5 8 sec minimum/16 sec maximum Maximum rate = 7500 cps. 6 16 sec minimum/32 sec maximum Maximum rate = 3250 cps.

1 x1000 2 x100 3 x10 4 x1 5 x0.1 6 x0.01

(+) Leading Zero Blanking Enabled (-) Leading Zero Blanking Disabled*

-42-

APPENDIX “D” - GEMINI 5200 DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY

CODE MODE DESCRIPTION COMMENTS

46 RATE B DECIMAL POINT & LEAD ZERO BLANKING

+/-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

51 OUTPUT ASSIGNMENT

+/-1 Output 1 to Rate A, Output 2 to Rate B +/-2 Outputs1&2toRate B +/-3 Outputs1&2toRate A

52 OUTPUT 1 TERMINATION MODES

+/-3 Terminate at Manual Reset +/-4 Terminate at Manual Reset End +/-5 Terminate after Timed Output 1

+/-6 Boundary 53 TIMED OUTPUT 1 VALUE Range 0.01 to 599.99 sec. 54 OUTPUT 2 TERMINATION MODES

+/-3 Terminate at Manual Reset

+/-4 Terminate at Manual Reset End

+/-5 Terminate after Timed Output 2

+/-6 Boundary 55 TIMED OUTPUT 2 VALUE Range 0.01 to 599.99 sec.

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

(Cont’d)

(+) Preset Tracking disabled (-) Preset Tracking enabled* Preset 1 tracks Preset 2

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

-43-

APPENDIX “D” - GEMINI 5200 DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY

CODE MODE DESCRIPTION COMMENTS

56 RATE B RIGHT-HAND DUMMY ZEROS

61 RATE A RIGHT-HAND DUMMY ZEROS

62 RATE A CONVERSION FACTOR

63 RATE A MINIMUM UPDATE TIME

64 RATE A SCALE MULTIPLIER

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

1 1 Dummy Zero 2 2 Dummy Zeros 3 3 Dummy Zeros 4 No Dummy Zeros

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

1 x1000 2 x100 3 x10 4 x1 5 x0.1 6 x0.01

-44-

APPENDIX “D” - GEMINI 5200 DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY

CODE MODE DESCRIPTION COMMENTS

65 RATE A DECIMAL POINT & LEAD ZERO BLANKING

+/-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 66 “OPERATOR ACCESSIBLE FUNCTIONS” MODES “PGM DIS” Terminal connected to “Comm”

+/-1 No Functions Enabled

+/-2 Preset Programming Enabled

+/-3 Scale Factor Programming Enabled

+/-4 Preset & Scale Factor Programming Enabled

1 PRESET 1 Up to +/-999999 2 PRESET 2 3 Display A RATE A SCALE FACTOR Up to 5.9999 3 Display B RATE B SCALE FACTOR

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

(+) Leading Zero Blanking Enabled (-) Leading Zero Blanking Disabled*

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

the Input Configuration DIP switch.

(-) Reset Button & “RST” Terminal Disabled* This mode has no affect on the “RST A” terminal which is

always enabled.

-45-

APPENDIX “E” - GEMINI 5200 DUAL RATE W/ DISP C FUNCTION COMMAND CODE SUMMARY

CODE MODE DESCRIPTION COMMENTS

41 UNIT PERSONALITY (-)Loads factory set code values*

42 RESET BUTTON & TERMINAL ACTUATION MODES

43 RATE B CONVERSION FACTOR

45 RATE B SCALE MULTIPLIER

46 DISPLAY C DECIMAL POINT & LEAD ZERO BLNKNG

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

+/-1 Dual Rate W/O Display C See Appendix "D" for function command code summary.

+/-2 Dual Rate W/ Ratio (A/B) RateA&BÞDisplay valueA&B,

Ratio (A/B)ÞDisplay Value C

+/-3 Dual Rate W/ Difference (A-B) RateA&BÞDisplay valueA&B,

Difference (A-B)ÞDisplay Value C

+/-4 Dual Rate W/ Draw [(A-B)/B] RateA&BÞDisplay valueA&B,

Draw [(A-B)/B]ÞDisplay Value C

1 Reset Rate A Output(s) Reset only affects the output(s) and does not 2 Reset Rate B Output(s) change the rate display. 3 Reset RateA&BOutputs 4 Reset Display C Output(s) 5 Reset Display C & Rate A Outputs 6 Reset Display C & Rate B Outputs

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

1 x1000 2 x100 3 x10 4 x1 5 x0.1 6 x0.01

(+) Leading Zero Blanking Enabled (-) Leading Zero Blanking Disabled*

+/-1 No Decimal Point

-46-

APPENDIX “E” - GEMINI 5200 DUAL RATE W/ DISP C FUNCTION COMMAND CODE SUMMARY

CODE MODE DESCRIPTION COMMENTS

46 DISPLAY C DECIMAL POINT & LEAD ZERO BLNKNG

+/-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

51 OUTPUT ASSIGNMENT

+/-1 Output 1 to Rate A, Output 2 to Rate B +/-2 Outputs1&2toRate B +/-3 Outputs1&2toRate A +/-4 Output 1 to Rate B, Output 2 to Display C +/-5 Output 1 to Rate A, Output 2 to Display C +/-6 Outputs1&2toDisplay C

52 OUTPUT 1 TERMINATION MODES

+/-3 Terminate at Manual Reset +/-4 Terminate at Manual Reset End +/-5 Terminate after Timed Output 1

+/-6 Boundary 53 TIMED OUTPUT 1 VALUE Range 0.01 to 599.99 sec. 54 OUTPUT 2 TERMINATION MODES

+/-3 Terminate at Manual Reset

+/-4 Terminate at Manual Reset End

+/-5 Terminate after Timed Output 2

+/-6 Boundary

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

(Cont’d)

(+) Preset Tracking disabled (-) Preset Tracking enabled* Preset 1 tracks Preset 2

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

-47-

APPENDIX “E” - GEMINI 5200 DUAL RATE W/ DISP C FUNCTION COMMAND CODE SUMMARY

CODE MODE DESCRIPTION COMMENTS

55 TIMED OUTPUT 2 VALUE Range 0.01 to 599.99 sec. 61 DISPLAY C MULTIPLIER Not available in mode [41 3], Speed Difference

62 RATE A CONVERSION FACTOR

63 RATE MINIMUM UPDATE TIME

64 RATE A SCALE MULTIPLIER

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

1 x1 2 x10 3 x100 4 x1000 5 x10000

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

1 x1000 2 x100 3 x10 4 x1 5 x0.1 6 x0.01

-48-

APPENDIX “E” - GEMINI 5200 DUAL RATE W/ DISP C FUNCTION COMMAND CODE SUMMARY

CODE MODE DESCRIPTION COMMENTS

65 RATEA&BDECIMAL POINT & LEAD ZERO BLNKNG

+/-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

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

+/-1 No Functions Enabled

+/-2 Preset Programming Enabled

+/-3 Scale Factor Programming Enabled

+/-4 Preset & Scale Factor Programming Enabled

1 PRESET 1 Up to +/-999999 2 PRESET 2 3 Display A RATE A SCALE FACTOR Up to 5.9999 3 Display B RATE B SCALE FACTOR

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

(+) Leading Zero Blanking Enabled (-) Leading Zero Blanking Disabled*

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

DIP switch.

(-) Reset Button & “RST” Terminal Disabled* This mode has no affect on the “RST A” terminal which is

always enabled.

-49-

APPENDIX “F” - SCALING FOR RATE & DISPLAY C

The Gemini 5200 offers a simplified method of scaling the rate indicator. The method does not require timeunit conversions. The desired timeformat (Rate Per Second, Rate Per Minute, Rate Per Hour) is simply selected as part of the programming procedure.

Due to the way the rate is calculated, high resolution and accuracy can be realized at allinput rates,slow or fast. Itis not necessary toincrease the number of pulses per display unit to obtain higher resolution.

The Rate Minimum Update Time, function code 63, can be increased (from

0.5 Sec.up to 16 Sec.) to provideaveraging in applications where the inputpulse spacing is not stable. The Update time selected, however, will not affect the scaling in any manner.

Scaling the Rate channel simply involves programming the Gemini 5200 so that pulse units inputted to the unit will be scaled to the desired display units (revolutions, feet, meters, etc.), in the desiredtime format (Rate Per Second, Rate per Minute, Rate Per Hour).

In order to scale the rate, it is only necessary to know the number of pulses per “Display Unit” or units (feet, revolutions, etc.). For example; if a 48 tooth gear, which is coupled to a shaft, is being sensed and it is desired to indicate the shaft speed inrevolutions, the “Display Units” would be revolutions. It is obvious that 48 pulses will occur in one revolution.

In orderto convertthe pulseunits to revolutions, it is necessary for the Gemini 5200 to multiply the number of pulses by a scaling factor to convert the pulse units to revolutionunits. TheGemini 5200 has twoprogramming codes that serve to scale pulse units to desired display units. They are: the Scale Factor and the Scale Multiplier. Both are used to attain the Total Scaling Factor, “K

To calculatethe Total Scaling Factor, “KT”, for theapplication, the following

”.

formula is used.

FORMULA #1: K

= Display Units/Number of Pulses

WHERE:

DISPLAY UNITS

- The number of units(revolutions, feet,10ths of feet, meters,

etc.) that would be acquired after the “Number of Pulses” has occurred.

NUMBER OF PULSES

- The Numberof pulsesrequired toachieve thenumber

of “Display Units”.

Using the example previously discussed, the display unit would be 1 revolution and the number of pulses per display unit would be 48. Therefore, the Total Scale Factor would be 0.020833 (K rev/48 pulses per rev = 0.020833). In many applications the Total Scale Factor, “K

”, can be programmed as the Scale Factor, “SF”, and the Scale Multiplier

factory setting, x1, would be used. However, in some applications, such as the

= Display Units/ Number of Pulses =1

one above, it may be desired toobtain more significant digits in the Scale Factor, “SF”. These situations occur when the “K that canbe entered into the four decimal places available tothe Scale Factor. The

” factor does not calculate to a number

following formula can be used to calculate the Scale Factor when a SCM value other than x1 is needed.

FORMULA #2: SF=K

/SCM

In this formula, the Total Scaling Factor, previously calculated, is divided by the Scale Multiplier Value, “SCM”, to obtain the Scale Factor, “SF”.

The general rule for choosing a SCM value is, when the Total Scale Factor, “K

”, is less than 0.6000, a SCM value of 0.1 or 0.01 can be used to get a Scale

Factor value between 0.6 and 5.9999, or to the point where the maximum number of significant digits is obtained. If the Total Scaling Factor, “K

5.9999, then a SCM value of 10, 100, or 1000 can be used to obtain a Scale Factor

”, is greater than

Value between 0.6 and 5.9999.

In our initial example, the Total Scaling Factor, “K

0.020833. It is easy to see that this number cannot be programmed into the Scale

”, was determined to be

Factor, “SF”, without losing significantdigits. Using formula #2 and the general rules stated above, a ScaleMultiplier Value of 0.01 ischosen and the Scale Factor is calculated as shown below. This will provide the maximum amount of conversion accuracy possible.

SF=K

/SCM

SF = 0.020833/SCM SF = 0.020833/0.01 = 2.0833

-50-

In situations where the Total Scale Factor is already in range of the Scale Factor (0.0001 to 5.9999) and when there are no significant digits lost, the Total Scaling Factor, “K and a Scale Multiplier value of 1 (the factory set value)can beused. Forexample;

”, can be programmed directly into the Scale Factor Value

if the display units are in feet and there are 100 pulses per foot, the Total Scaling Factor, “K

0.01). Since the Total ScalingFactor, “K into the Scale Factor Value, “SF”. The Scale Multiplier Value, “SCM”, can be

”, would be 0.01 ( KT= Display Units/Number of Pulses = 1/100 =

”, is exactly 0.01, itcan be programmed

left at or programmed to its factory setting of x1.

After the Scale Factor and Scale Multiplier values are selected, all that is necessary to complete the scaling is to choose the Rate Conversion Factor. The Rate ConversionFactor canbe selectedto provideindication in Rate per Second, Rate Per Minute, or Rate per Hour.

Note: There may be situations where there are many more pulses per display unit

than needed. In these situations the minimum SCM value (0.01) may not

provide enough significant digits in the Scale Factor. To achieve more

significant digits, the Rate Conversion Factor should be set to mode 1, Rate

per Second, and the following formula should be used.

SF = K

xCF

SCM

Where: CF = 60 for display reading in Rate Per Minute, or

CF = 3600 for display reading in Rate Per Hour

SCALING DISPLAY C

In the Speed Ratio and Speed Draw modes, [41 2,4], Display C can be scaled in order to obtain the desired amount of decimal point resolution. This is accomplished by selecting a “Display C Multiplier” and the proper “Display C Decimal Point & Leading Zero Blanking” mode.

In the Speed Ratio and Speed Draw modes the Gemini 5200 performs the appropriate Display C calculation based upon the measured internal rate value, utilizing the total number of significant digits available to it. It does not use the amount of resolution that is used in the Rate A & B displays. For example; if the Gemini 5200 was set-up in mode [41 2], Dual Rate with Speed Ratio, and therate indicators were programmed to indicate rate with no decimal point. With actual rates of 1.5 PPS for Rate A, and 1 PPS for Rate B the rate displays would both read 1, however, Display C, when using a Display C Multiplier of 10 and a decimal point, would read 1.5 (C = A/B = 1.5/1 = 1.5).

RATE SCALING EXAMPLES

EXAMPLE #1:

A 60 tooth gear is mounted to a roller that has a circumference of 2 feet. It is desired to have a rate readout in 10ths of feet per minute. Calculate the Scale Factor and Scale Multiplier values necessary to provide the desired readout.

In this example one revolution of the rollerwill provide 60 pulses for 2 feet of linear travel. Since the desired display units are to be in tenths of feet, it is necessary to convert 2 feetto tenths,giving us 20 tenths(display units).The Total Scaling Factor, “K formula #1.

In order to get the maximum number of significant digits in the Scale Factor we use formula #2 and a Scale Multiplier value of 0.1 as shown below.

To obtain rate indication in Feet Per Minute, the Rate Conversion Factor is programmed for Rate per Minutemode. A decimal point is also added to provide for a display of feet in 10ths.

EXAMPLE #2:

The shaft of a positivedisplacement pump hasa 14 toothsprocket thatis being sensed bya magneticpickup. It is known that when the unit is pumping 810 liters of water per minute, the shaft is turning 400 RPM. It is desired to have a display readout in liters per minute.

With theGemini 5200, itis not necessaryto deal withtime unit conversions.From the information given, we know that when the shaft has turned 400 revolutions, 810 liters of water will have been pumped. The first step we need to take, is to calculate the number of pulses that occur when 810 liters have been pumped.

NUMBER OF PULSES = # of Revolutions x Pulses per Rev.

NUMBER OF PULSES = 400 Rev x 14 Pulses per Rev = 5600 pulses.

”, is calculated by simply plugging in the two numbers into

= Display Units/Number of Pulses

= 20/60 = 0.333333

SF=K

/SCM

SF = 0.333333/0.1 = 3.3333

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RATE SCALING EXAMPLES (Cont’d)

We now haveall theinformation necessaryto scalethe rate.The Total Scaling

Factor “K

“K maximum amount of significant digits for the Scale Factor, Formula #2 is used and a Scale Multiplier value of 0.1 is selected.

places). This provides the maximum amount of conversion accuracy possible.

Factor is chosen to be Rate Per Minute as was required.

”, is calculated using Formula #1 as shown below.

= Display Units/Number of Pulses

= 810/5600 = 0.144643

It is noticed that there are more significant digits in the Total Scale Factor,

”, than there are available for Scale Factor, “SF”. In order to acquire the

SF=K

/SCM

SF = 0.144643/0.1 = 1.4464

The Scale Factor, “SF”, then becomes 1.4464 (1.44643 rounded to 4 decimal

The final step is to select a Rate Conversion Factor. The Rate Conversion

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APPENDIX “H” - ORDERING INFORMATION

MODEL NO. DESCRIPTION W/20 mA Current Loop

GEM52 Gemini 5200 No GEM52060

Yes GEM52160

For Information on Pricing, NEMA Enclosures, Base Mount Kits, & Panel Adapter Kits, refer to the Red Lion Controls Catalog or contact your local RLC distributor.

Gemini 5200 Relay Board RLYBD002

PART NUMBERS

115/230 VAC

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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

GEM52 / IM - I 4/05 DRAWING NO. LP0161

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 52 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual