Alstom GEM80-400 Series User manual

GEM80-400 Series Controllers
Technical Manual
ABCD

ALSPA GEM80-400
Series Controllers
Technical Manual
Publication No. T1614
Issue 3

Issue 3 04/99 ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Page i
ALSPA GEM80-400
SERIES CONTROLLERS
Technical Manual
Publication No. T1614
ALSTOM DRIVES & CONTROLS,
Kidsgrove,
Stoke-on-Trent,
Staffordshire, ST7 1TW
ENGLAND
Telephone: [phone]
Fax: [phone]
Latest Reprint: see page ii

Issue Information GEM80-400
Page ii ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04/99
ISSUE INFORMATION
The issue of various chapters of the GEM80-400 manual are individually
controlled. The current issue status of the manual is :-
20/01/98
Issue 2
Major revisions to all sections
20/04/99
Issue 3
Inclusion of GEM80-400S Controller and minor corrections
to all sections.

GEM80-400 Safety Instructions
Issue 3 04/99 ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Page iii
SAFETY INSTRUCTIONS
1. General
Electrical equipment represents a risk to life.
Safety instructions are given on the product, in this manual and other relevant
manuals referred to in this manual.
Reference must be made to the instructions in this manual for any action taken
when transporting, commissioning, operating, maintaining and disposing of the
product.
Dangerous voltages appear on the circuitry. There can be moving parts and hot
surfaces. Death, severe physical injury and extensive material damage can result
if the instructions given in this manual are not observed.
Local safety regulations must be observed during erection, commissioning and
maintenance of the product. Persons performing this work must be suitably
skilled and should have been trained in that work for these products.
Electrostatic sensitive components are used within this product. Static handling
precautions in accordance with Protection of Electrostatic Sensitive Devices,
Part 1, General Requirements, EN 100015 Pt.1:1992 (CECC 00015:1992) must be
observed.
All products weighing in excess of 20kg (44 lbs) should be moved by mechanical
handling equipment using the lifting points provided.
Radio transmitters (e.g. walkie talkies, mobile telephones) can cause incorrect
operation. Transmitters with an output of more than 2 watts must not be used in
the vicinity of the product. Transmitters with output power of 2 watts or less must
not be used less than 2 metres (6 feet) from the product.
2. Intended use
These products are components designed for incorporation in installations,
apparatus and machines.
In the European Union, a machine should not be taken into service until the
machine has been proven to conform with the provisions of the Machinery
(Safety) Directive, 89/392/EEC as amended.
In the European Union, the requirements of the EMC Directive, 89/336/EEC, and
any amendments to that Directive should be established before any installation,
apparatus or machine which incorporates the product is taken into service.
The product complies with the requirements of the Low Voltage Directive,
73/23/EEC as amended.

Safety Instructions GEM80-400
Page iv ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04//99
The product complies with the safety and EMC standards listed in the
Specifications section of the manual.
The technical data and the information concerning the supply conditions should
be taken from the rating plate and this manual, and must be strictly observed.
3. Transportation and storage.
The instructions for storage and transport specified on the packaging and in this
manual must be followed.
The climatic conditions should be within the limits specified in this manual.
4. Erection and commissioning.
Erection and commissioning of, and cooling medium flow to, the product should
be in accordance with the specifications given in the manual.
Erection and commissioning of the product must be carried out in line with any
local electrical installation and wiring standards and IEC 364 or (in the United
Kingdom) BS 7671.
The earth terminal must be connected to earth (safety ground) in accordance
with local safety regulations and IEC364-5-54.
The products must be protected against excessive mechanical stresses. In
particular, no component must be bent or isolation distances altered during the
transportation, handling, installation or maintenance of the product.
The degree of protection provided by the covers is for indoor use only.
Compliance with the requirements of EMC laws is the responsibility of the installer
or the manufacturer of the machine. Instructions for erection and commissioning
the product in accordance with the EMC requirements of the European Union
are given in the manual and must be complied with. These instructions contain
information on screening (shielding), earthing (grounding), wiring and relative
positioning of electrical equipment.
Shrouds may be modified only as described in the manual.
5. Electrical connection
When working on the product, the local health and safety legislation must be
observed.
Conductors, protective devices etc. should be provided in accordance with the
requirements stated in the manual.
6. Operation

GEM80-400 Safety Instructions
Issue 3 04/99 ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Page v
The product must not be used as a single item safety system. It may be used as
a component in a voting safety system. Additional control and protective
devices must be provided in accordance with the safety requirements of the
installation.
Changes by means of the application software are admissible.
During operation all covers and doors must be closed. If covers are removed
and not replaced before power is reapplied there is danger of serious personal
injury and damage to property. Your attention is also drawn to the
electromagnetic emission and susceptibility screening provided by the
enclosure. These may be compromised when covers are removed or enclosure
doors are open.
7. Maintenance and service
The information given in the documentation for maintaining and servicing the
product must be followed.
8. Disposal
Local regulations must be followed when disposing of the product.
This technical manual should be regarded as part of the product. It should be
stored with the product and passed on to any subsequent owner or user of the
product.
Any question or doubt should be referred to ALSTOM DRIVES & CONTROLS

COSHH GEM80-400
Page vi ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04/99
CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH
1. GENERAL
Care has been taken with selection of all components, interconnections, housing
and packaging and in the design and manufacture of this equipment to
minimize the risk to the health and safety of all personnel who are in contact with
this equipment during its life, when the equipment is properly handled and used.
Modern high technology materials have been used in the manufacture of the
equipment to ensure optimum performance. Some of these materials are toxic
under certain conditions. Mechanical or electrical damage is unlikely to give rise
to any direct hazard, but toxic vapours may be generated if the materials are
heated to destruction and it is important that the recommendations given below
are observed.
Care should be taken to ensure that all personnel who may handle, use or
dispose of this equipment are aware of the necessary precautions.
2. DISPOSAL
This equipment or any part of the equipment should be disposed of in
accordance with the relevant legislation; in the United Kingdom, disposal should
therefore be carried out in accordance with the Deposit of Poisonous Waste Act
1972 and the Control of Pollution Act 1974, or with the latest legislation.
Some devices within this equipment may contain beryllium oxide as an isolating
barrier. Such devices must be disposed of as harmful waste.
3. FIRE
The products when used within the specified limits do not present a fire hazard.
Electronic devices within this equipment may contain arsenic, beryllium, lead,
mercury, selenium, tellurium or similar hazardous materials or compounds which,
if exposed to high temperature may emit toxic or noxious fumes.
Most device encapsulation materials are flammable and care should be taken
in the disposal of the equipment, and, in the event of a fire, the handling of
damaged equipment. Toxic fumes may be emitted if the devices are burned.
4. HANDLING
Normal handling of the equipment is safe. However, care must be exercised
with those devices incorporating glass or plastic. If these devices are broken or
damaged, precautions must be taken against the hazards that may arise.

GEM80-400 COSHH
Issue 3 04/99 ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Page vii
For broken glass or ceramic protective clothing such as gloves must be worn.
For toxic materials, vapour, skin contact and inhalation must be avoided.
5. SUBSTANCES
Substances that may be included in this equipment are:-
Arsenic
Boric acid
Ethylene Glycol
Phosphoric acid
Phthalic acid
Tributylamine
Triethylamine
Certain substances such as those containing arsenic, indium, lead, lithium,
selenium, tantalum, etc. may be toxic by ingestion or inhalation.
Electrolytic capacitors contain a non carcinogenic electrolyte which has a low
acute toxicity which may cause slight irritation to the skin if contact is prolonged.
6. HAZARDOUS COMPONENTS
Components that may include hazardous substances are:-
Batteries
Lithium
Optical Devices
Arsenic
Electrolytic capacitors
Electrolyte.
All encapsulated Devices
Plastic (generates an inhalation risk in
a fire).
7. PRECAUTIONS
Precautions to be followed in the event of damage to the equipment except
where special precautions to be followed are listed above, include:-
After skin contact
-
wash thoroughly with soap and water. If contact is
where the skin is broken, medical advice should be
sought.
After eye
contact
-
wash immediately with copious amounts of water
and seek medical advice.
After inhalation
-
seek medical advice.

COSHH GEM80-400
Page viii ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04/99
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GEM80-400 Table of Contents
Issue 3 04/99 ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Page ix
Table of Contents
Issue Information .......................................................................................................................... ii
Safety Instructions.........................................................................................................................iii
Control of Substances Hazardous to Health..............................................................................vi
Table of Contents......................................................................................................................... ix
Product Overview......................................................................................................................xxi
1. Introduction.......................................................................................................................xxi
2. GEM 80-400 Series Controller Facilities ............................................................................xxi
2.1. Serial Links .................................................................................................................xxi
2.2. Real Time Clock........................................................................................................xxi
2.3. RAM...........................................................................................................................xxi
2.4. Input Output Systems.............................................................................................. xxii
2.4.1. Basic and Verification I/O.............................................................................. xxii
2.4.2. Fast I/O............................................................................................................ xxii
3. Additional User Programming Facilities.......................................................................... xxii
3.1. Ladder Diagram Enhancements........................................................................... xxii
3.2. Rack Id.....................................................................................................................xxiii
3.3. GEM 80-400 Alphanumeric Display......................................................................xxiv
3.4. System Log..............................................................................................................xxiv
3.5. Architecture Improvements..................................................................................xxiv
4. Expandability and Adaptability.....................................................................................xxiv
4.1. User Program Storage Capacity...........................................................................xxiv
4.2. User Program Storage in EPROM...........................................................................xxiv
4.3. I/O Modules.............................................................................................................xxv
4.4. FIP .............................................................................................................................xxv
5. GEM 80-400S and 400 Enhanced System Specific Features ........................................xxv
5.1. Central Highway .....................................................................................................xxv
5.2. IMAGEM CRT Monitor Frequency Selection.........................................................xxvi
5.3. Fast I/O capability..................................................................................................xxvi
5.3.1. Fast I/O with GEM80/400S Controllers..........................................................xxvi
5.3.2. Fast I/O with GEM80-400 Enhanced Controllers .........................................xxvi
6. Compatibility.................................................................................................................. xxvii
6.1. I/O........................................................................................................................... xxvii
6.2. User Program ......................................................................................................... xxvii
7. Maintenance and Installation Cost Reduction Features........................................... xxvii
7.1. System Level Considerations................................................................................ xxvii
7.2. Spares.....................................................................................................................xxviii
7.3. Alphanumeric Display...........................................................................................xxviii
7.4. System Log.............................................................................................................xxviii
7.5. Key Switch............................................................................................................... xxix
7.6. Battery......................................................................................................................xxx
7.7. Controller Firmware Update...................................................................................xxx
1. Introduction............................................................................................................................1-1
1.1. Manual Overview..........................................................................................................1-1
1.1.1. Chapter 1 - Introduction......................................................................................1-1
1.1.2. Chapter 2 - Controller Architecture and Program Operation.........................1-1
1.1.3. Chapter 3 - I/O Highway .....................................................................................1-1
1.1.4. Chapter 4 - Communications .............................................................................1-1
1.1.5. Chapter 5 - Central Highway Modules..............................................................1-1
1.1.6. Chapter 6 - Power Supplies.................................................................................1-2

Table of Contents GEM80-400
Page x ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04/99
1.1.7. Chapter 7 - Installation.........................................................................................1-2
1.1.8. Chapter 8 - Commissioning.................................................................................1-2
1.1.9. Chapter 9 - Maintenance and Fault Finding.....................................................1-2
1.1.10. Chapter 10 - Spares and Reorder Codes ........................................................1-2
1.1.11. Chapter 11 - Watchdog and Safety Circuits...................................................1-2
1.2. General Information.....................................................................................................1-2
1.3. GEM 80-400 Series Controller........................................................................................1-3
1.4. GEM 80-400 Controller System....................................................................................1-5
1.4.1. Processor Module.................................................................................................1-6
1.4.2. Power Supply........................................................................................................1-6
1.4.3. Backplanes...........................................................................................................1-6
1.4.4. Basic and Verification I/O Highways ..................................................................1-7
1.4.5. Serial Communication Links.................................................................................1-7
1.4.6. Printer/Programming Connection Port...............................................................1-7
1.4.7. Watchdog Contacts............................................................................................1-7
1.4.8. Fast I/O Driver .......................................................................................................1-7
1.4.9. Video Processor Outputs.....................................................................................1-8
1.4.10. Additional Facilities ............................................................................................1-8
1.5. GEM 80-400 Controller System....................................................................................1-8
1.5.1. Subrack Assembly................................................................................................1-8
1.5.1.1. Mechanical Structure..................................................................................1-8
1.5.1.2. Controller Subrack Labelling.......................................................................1-9
1.5.1.3. Fitting Controller Modules...........................................................................1-9
1.6. GEM 80-400 Controller Modules Description .............................................................1-9
1.6.1. 8239 Processor Module........................................................................................1-9
1.7. 9032 Power Supply......................................................................................................1-11
1.8. 9017/ 9018 Power Supply Module..............................................................................1-12
1.9. I/O Modules.................................................................................................................1-12
1.10. Central Highway Modules........................................................................................1-13
1.10.1. 8272 Memory Module (RAM)...........................................................................1-13
1.11. GEM80-400 Controller Backplanes Description......................................................1-17
1.11.1. Upper Backplane.............................................................................................1-17
1.11.2. Lower Backplane..............................................................................................1-19
1.12. Specification..............................................................................................................1-21
1.13. Site Requirements .....................................................................................................1-22
1.13.2. Environment......................................................................................................1-22
1.13.3. Power Supply Requirements............................................................................1-23
1.13.4. Receipt of GEM 80-400 Processor Module....................................................1-23
1.13.5. Storing GEM 80 Before Installation ..................................................................1-24
1.13.6. Radio Frequency Interference (RFI)................................................................1-24
1.13.7. Transmitter Output............................................................................................1-25
1.14. Handling Precautions for Printed Circuit Boards ....................................................1-25
1.14.2. Introduction ......................................................................................................1-25
1.14.3. Protection of Equipment from Static Damage..............................................1-25
1.14.4. Protection During Arrival, Handling and Storage at Site...............................1-26
1.14.5. Protection During Setting Up of Equipment...................................................1-26
1.14.6. Protection During Maintenance and Spares Handling ................................1-26
1.14.7. Reference Reading..........................................................................................1-26
1.14.8. Recommended Antistatic Equipment ...........................................................1-27
1.15. Safety and Handling Information ............................................................................1-27
1.15.2. Earthing.............................................................................................................1-27
1.15.3. High Voltages ...................................................................................................1-27
1.15.4. Power Down Before Removing Modules or Connectors..............................1-27
1.15.5. Power Down Safety Procedure.......................................................................1-27
1.15.6. On-line Programming.......................................................................................1-27

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1.15.7. Testing a GEM 80 System................................................................................. 1-28
1.15.8. Watchdog and Safety Circuits .......................................................................1-28
1.15.9. System Status Indication..................................................................................1-28
1.16. GEM 80 Batteries - Safety Precautions for Disposal and Handling........................1-28
1.16.2. Handling............................................................................................................1-28
1.16.3. Disposal.............................................................................................................1-29
1.16.4. Damage............................................................................................................1-29
2. Controller Architecture and Program Operation................................................................2-1
2.1. Controller Architecture.................................................................................................2-1
2.2. Operation Cycle...........................................................................................................2-2
2.2.1. Start-up Procedure, Initialisation.........................................................................2-5
2.2.2. Operating Cycle, Operation Phase ...................................................................2-5
2.2.3. Fault Shutdown Procedure, Error Handling........................................................2-5
2.3. System Self-tests ............................................................................................................2-6
2.4. States of the GEM 80-400 Controller...........................................................................2-6
2.4.1. Halted, Normal Inputs..........................................................................................2-7
2.4.2. Halted, Test Inputs................................................................................................2-7
2.4.3. Running, Normal Inputs........................................................................................2-7
2.4.4. Running, Test Inputs..............................................................................................2-7
2.4.5. Non-Fatal Shutdown............................................................................................2-8
2.4.6. Fatal Shutdown.....................................................................................................2-8
2.4.7. Extremely Fatal Shutdown...................................................................................2-8
2.5. Serial Communications.................................................................................................2-9
2.6. Program Scan Times .....................................................................................................2-9
2.6.1. Free-running Cycle Time......................................................................................2-9
2.6.2. Preset Cycle Time.................................................................................................2-9
2.6.3. Calculating the Program Scanning Interval ....................................................2-10
2.7. Program Operation.....................................................................................................2-11
2.7.1. Programmer Units...............................................................................................2-11
2.7.2. Remote Programming .......................................................................................2-11
2.7.3. Program and Data Table Capacity .................................................................2-12
2.7.4. Message Output Facility....................................................................................2-12
2.7.5. Connecting a Suitable GEM 80 Programming Tool ........................................2-12
2.7.6. Program Compilation ........................................................................................2-12
2.7.7. On-line Program Changes.................................................................................2-13
2.7.8. Off-line Program Debugging.............................................................................2-13
2.7.9. Loading Programs..............................................................................................2-14
2.7.10. Programming the Controller............................................................................2-14
2.8. User Program...............................................................................................................2-14
2.8.1. Introduction........................................................................................................2-14
2.8.2. Ladder Diagram Language..............................................................................2-14
2.8.3. Instruction Set .....................................................................................................2-16
2.9. GEM80 Special Functions...........................................................................................2-23
2.9.1. Introduction........................................................................................................2-23
2.9.2. Array and Group GEM 80 Special Functions ...................................................2-23
2.9.3. Implied Addresses in GEM 80 Special Functions..............................................2-23
2.9.4. Use of Floating Point GEM 80 Special Functions..............................................2-23
2.9.5. Program Capacity.............................................................................................2-23
2.10. Program Development.............................................................................................2-24
2.11. Programming Procedures........................................................................................2-24
2.11.1. CLEAR STORE.....................................................................................................2-24
2.11.2. Declare Highest Address.................................................................................2-24
2.11.3. Storing Programs...............................................................................................2-25
2.11.4. Storing Program and Presets in EPROM.......................................................... 2-25
2.11.5. Transferring Program and Presets to EPROM .................................................2-26

Table of Contents GEM80-400
Page xii ALSPA GEM80-400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04/99
2.11.6. Programming EPROM.......................................................................................2-26
2.12. Watchdog Trip Initiated by User Program...............................................................2-28
2.13. Data Tables................................................................................................................2-29
2.13.1. Data Table Addressing .................................................................................... 2-29
2.13.2. Data Storage Formats......................................................................................2-30
2.13.2.1. Integer Numbers......................................................................................2-30
2.13.2.2. Decimal....................................................................................................2-30
2.13.2.3. Hexadecimal............................................................................................2-30
2.13.2.4. Text............................................................................................................2-30
2.13.2.5. Floating Point Numbers ...........................................................................2-31
2.13.3. Data Table Content and Addresses...............................................................2-31
2.13.4. Data Table Sizes................................................................................................2-31
2.13.5. Action of Clear Store on Data Tables.............................................................2-32
2.13.5.1. P-Data Table ............................................................................................2-34
2.13.6. E-Data Table.....................................................................................................2-35
2.13.7. Real Time and Date.........................................................................................2-35
2.13.8. Program Scan Times.........................................................................................2-36
2.13.9. F-Data Table .....................................................................................................2-36
2.13.10. I-Data Table ....................................................................................................2-37
2.13.11. J/K-Data Tables ..............................................................................................2-37
2.13.12. R-Data Table...................................................................................................2-37
2.13.13. V-Data Table...................................................................................................2-38
2.14. GEM 80-400 Additional Instructions .........................................................................2-38
2.14.1. Set/Reset Coils..................................................................................................2-38
2.14.1.1. Function....................................................................................................2-38
2.14.1.2. Format.......................................................................................................2-38
2.14.1.3. Operation.................................................................................................2-38
2.14.1.4. Program Entry...........................................................................................2-39
2.14.1.5. Programming Rules..................................................................................2-39
2.14.1.6. Monitoring................................................................................................2-39
2.14.1.7. Operation Within Blocks..........................................................................2-39
2.14.1.8. Print-Outs ..................................................................................................2-40
2.14.1.9. Application Notes....................................................................................2-40
2.14.1.10. Searching for Retentive Coils................................................................2-40
2.14.1.11. Compatibility with GEM 80 Programming Tools ..................................2-40
2.14.2. JUMP/LABEL.......................................................................................................2-40
2.14.2.1. Function....................................................................................................2-40
2.14.2.2. Format.......................................................................................................2-41
2.14.2.3. Operation.................................................................................................2-41
2.14.2.4. Program Entry...........................................................................................2-41
2.14.2.5. Programming Rules..................................................................................2-41
2.14.2.6. Monitoring................................................................................................2-42
2.14.2.7. Application Notes....................................................................................2-42
2.14.2.8. Searching for Jump/Label ......................................................................2-43
2.14.2.9. Comments Associated with Jump/Label..............................................2-43
2.14.2.10. Cross Referencing on Ladder Printout.................................................2-43
2.14.2.11. Compatibility with GEM 80 Programming Tools ..................................2-43
2.14.3. SEQELEM............................................................................................................2-43
2.14.3.1. Function....................................................................................................2-43
2.14.3.2. Format.......................................................................................................2-43
2.14.3.3. Operation.................................................................................................2-44
2.14.3.4. Program Entry...........................................................................................2-49
2.14.3.5. Application Notes....................................................................................2-49
3. I/O HIGHWAY.........................................................................................................................3-1
3.1. Introduction...................................................................................................................3-1

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3.2. Fault Reporting and Detection....................................................................................3-1
3.3. Typical I/O System.........................................................................................................3-2
3.4. Addressing I/O Modules in the Controller Subracks ..................................................3-3
3.4.1. GEM80/400S Controller........................................................................................3-3
3.4.2. Enhanced Controller............................................................................................3-3
3.4.3. Standard Controller .............................................................................................3-3
3.4.3.1. 8-Point Basic Modules..................................................................................3-4
3.4.3.2. 16-Point Basic Modules................................................................................3-4
3.4.3.3. 32-Point Basic Modules................................................................................3-5
3.5. Addressing Additional Basic I/O Modules ..................................................................3-5
3.5.1. 12-Slot I/O Subrack (8859-4003)...........................................................................3-5
3.5.1.1. 8-Point Modules ...........................................................................................3-6
3.5.1.2. 16-Point Modules .........................................................................................3-6
3.5.1.3. 32-Point Modules .........................................................................................3-7
3.6. Addressing Operator Interface Units (Basic I/O)........................................................3-7
3.7. Addressing Modules on the I/O Highway...................................................................3-7
3.8. Converting Verification I/O to Basic I/O.....................................................................3-8
3.8.1. Verification I/O Expander 8191-4004 ..................................................................3-8
3.8.1.1. Introduction..................................................................................................3-8
3.8.1.2. Address Setting............................................................................................3-9
3.8.1.3. Range Setting ..............................................................................................3-9
3.9. Fault Indication ...........................................................................................................3-11
3.9.1. Data Table Addresses........................................................................................3-13
3.10. Power for Basic and Verification I/O Equipment....................................................3-19
3.10.1. Introduction ......................................................................................................3-19
3.10.2. I/O Power Consumption..................................................................................3-19
3.10.3. Power for 8191 Verification I/O Expanders.....................................................3-20
3.10.4. Powering I/O Modules through the I/O Highway Ribbon Cables................3-21
3.10.5. Powering I/O Subracks from the Controller Power Supply Using Discrete
Wiring ............................................................................................................................3-23
3.10.6. Connecting an External Power Supply........................................................... 3-24
3.10.6.1. External +15V Power Source...................................................................3-24
3.10.7. Powering the Verification I/O Expander Module..........................................3-24
3.10.7.1. Powering via Ribbon Cables...................................................................3-24
3.10.7.2. Powering via Terminals on the Controller Backplane..........................3-25
3.10.8. Powering Verification I/O ................................................................................3-26
3.11. Basic and Verification I/O Ribbon Cables..............................................................3-26
3.11.1. 26-Way Ribbon Cable for Basic and Verification I/O Highway....................3-27
3.11.1.1. Standard Ready Assembled Cables......................................................3-27
3.11.2. Making Your Own Cables................................................................................3-27
3.12. Length Limits for 26-Way Basic I/O Ribbon Cables.................................................3-28
3.13. Segregation of 26-Way Basic and Verification I/O Highway Ribbon Cable.......3-28
3.14. I/O Module Interlock System.................................................................................... 3-28
3.14.1. I/O Module Interlock Circuit Ratings...............................................................3-30
3.15. Output Enable Modules...........................................................................................3-30
3.15.1. Output Enable Connections...........................................................................3-31
3.16. Wiring Segregation ...................................................................................................3-33
3.16.1. Wiring Size .........................................................................................................3-33
3.17. Example of Addressing.............................................................................................3-33
4. Communications...................................................................................................................4-1
4.1. Introduction...................................................................................................................4-1
4.1.1. Connecting Serial Ports 1 and 2..........................................................................4-2
4.2. GEM 80-400 to other GEM 80 Controllers....................................................................4-3
4.2.1. Communication Protocols...................................................................................4-3
4.2.2. Data Tables...........................................................................................................4-4

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4.2.3. Configuring the Serial Ports .................................................................................4-4
4.3. Serial Link Communication System..............................................................................4-5
4.3.1. Point-to-Point Serial Link.......................................................................................4-5
4.3.2. Multi-drop Serial Link.............................................................................................4-6
4.3.3. Serial Links Cabling and Connection..................................................................4-8
4.3.4. Using the Printer/Programming Port ...................................................................4-8
4.3.5. Printer/Programming Port (Port 3) Connections................................................4-9
4.4. Communication with a Printer, VDU or Suitable GEM 80 Programming Tool .......4-10
4.4.1. Specification.......................................................................................................4-10
4.4.1.1. Application.................................................................................................4-10
4.4.1.2. Characteristics...........................................................................................4-10
4.4.1.3. Capacity....................................................................................................4-10
4.4.1.4. Setting up a Printer/Keyboard Port.......................................................... 4-10
4.4.2. Operation of a Printer/Keyboard Port..............................................................4-11
4.4.2.1. Direct Mode...............................................................................................4-11
4.4.2.2. Terminal Mode...........................................................................................4-11
4.4.2.3. Free Format Mode.....................................................................................4-13
4.4.3. Operation of Printer/Terminal Buffer Store .......................................................4-13
4.4.4. Alphanumeric Input...........................................................................................4-14
4.4.5. Alphanumeric Output........................................................................................4-14
4.4.6. Editing Alphanumeric Output Messages ......................................................... 4-14
4.4.6.1. Printer Port Messages ................................................................................4-14
4.4.6.2. Using the Editor..........................................................................................4-15
4.4.6.3. Errors............................................................................................................4-17
4.5. Serial Communication Between Two or More GEM 80 Controllers (ESP Protocol)4-17
4.5.1. Operation as an ESP Tributary Port...................................................................4-18
4.5.1.1. Free-Running Mode...................................................................................4-18
4.5.1.2. User-Control Mode ....................................................................................4-18
4.5.2. Operation as an ESP Control Port.....................................................................4-18
4.5.2.1. Configuring Ports 1 and 2 as an ESP Control Port...................................4-22
4.5.3. J- and K-Tables for an ESP Control Port with Flexible Data Tables .................4-22
4.5.4. Operation as a Control Port..............................................................................4-23
4.5.4.1. Free-Running Mode...................................................................................4-23
4.5.4.2. User-Control Mode ....................................................................................4-23
4.5.4.3. Extended Time-out Option .......................................................................4-24
4.5.4.4. Broadcast Message Facility......................................................................4-24
4.6. GEMSTART CCU (Contactor Control Unit) ................................................................4-25
4.6.1. Introduction........................................................................................................4-25
4.6.2. P-Tables...............................................................................................................4-26
4.6.3. J/K-Tables............................................................................................................4-27
4.6.4. I-Tables ................................................................................................................4-27
4.6.5. User Specified Tables .........................................................................................4-27
4.6.6. F-Tables................................................................................................................4-28
4.7. Remote Programming................................................................................................4-28
4.8. Termination of Serial Links...........................................................................................4-28
4.9. Maximum Length of Serial Links.................................................................................4-28
4.10. Cable Connection Details .......................................................................................4-29
4.10.1. Cable.................................................................................................................4-29
4.10.2. Connectors.......................................................................................................4-29
4.10.3. Segregation......................................................................................................4-29
4.11. STARNET......................................................................................................................4-29
4.11.1. Introduction ......................................................................................................4-29
4.12. FIP Networks...............................................................................................................4-30
5. Central Highway Modules ....................................................................................................5-1
5.1. Introduction...................................................................................................................5-1

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5.2. Central Highway Processor Modules ..........................................................................5-2
5.3. Central Highway Ram Modules...................................................................................5-2
5.3.1. Off-line Memory....................................................................................................5-2
5.3.2. IMAGEM Memory.................................................................................................5-3
5.4. Fast I/O Equipment.......................................................................................................5-3
5.4.1. GEM80-400S Controller.........................................................................................5-3
5.4.2. GEM80-400 Enhanced Controller........................................................................5-3
5.5. Summary........................................................................................................................5-4
5.6. General Principles of Assigning Modules to Slots .......................................................5-4
5.7. IMAGEM.........................................................................................................................5-6
5.7.1. Introduction to IMAGEM......................................................................................5-6
5.7.2. L-Data Table .........................................................................................................5-8
5.7.3. Connecting Video Monitors................................................................................5-8
5.8. IMAGEM CRT Monitor Frequency Selection ...............................................................5-9
5.9. IMAGEM Compatibility.................................................................................................5-9
5.10. STARNET......................................................................................................................5-10
5.10.1. Introduction ......................................................................................................5-10
5.10.2. Power Supplies..................................................................................................5-12
5.11. GEMLAN-D.................................................................................................................5-12
5.11.1. Introduction ......................................................................................................5-12
5.11.2. Hardware..........................................................................................................5-14
5.11.3. Installation.........................................................................................................5-14
5.11.4. Operation..........................................................................................................5-14
5.11.5. Connections.....................................................................................................5-14
5.12. Fast I/O.......................................................................................................................5-15
5.12.1. Introduction ......................................................................................................5-15
5.12.2. Adding Fast I/O Equipment.............................................................................5-17
5.12.2.1. Adding Fast I/O to GEM80-400S Controllers ..........................................5-17
5.12.2.2. Adding Fast I/O to GEM80-400 Enhanced Controllers.........................5-17
5.12.3. C/D-Table Mapping for Fast I/O Input and Output Data.............................5-18
6. Power Supplies.......................................................................................................................6-1
6.1. Power Supply Requirements ........................................................................................6-1
6.2. Power Supply Specification .........................................................................................6-3
6.2.1. Controller Power Supply Module Specification.................................................6-3
6.2.2. Fast I/O Power Supply GEM80-400S Controller...................................................6-5
6.2.3. Fast I/O Subrack Power Supply Module.............................................................6-5
6.3. Controller Power Distribution and Consumption........................................................6-6
6.3.1. Power Consumed from Power Supply Module..................................................6-6
6.3.2. Controller Power Distribution...............................................................................6-7
6.4. Power Supply Connections..........................................................................................6-7
6.4.1. AC Fed Only .........................................................................................................6-7
6.4.2. DC Fed Only .........................................................................................................6-8
6.4.3. AC and DC Fed....................................................................................................6-9
6.4.4. -15VDC Fast I/O Power Supply..........................................................................6-10
7. Installation..............................................................................................................................7-1
7.1. Subrack Specification...................................................................................................7-1
7.1.1. Specification.........................................................................................................7-1
7.2. Mounting .......................................................................................................................7-2
7.2.1. Front Flange Mounting.........................................................................................7-2
7.2.2. Rear Flange Mounting.........................................................................................7-3
7.3. Subrack Spacer/Wiring Tray.........................................................................................7-3
7.4. Installing GEM 80 in a cubicle......................................................................................7-3
7.4.1. Introduction..........................................................................................................7-3
7.4.2. Equipment Layout................................................................................................7-4

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7.4.3. Examples of Cubicle Layout................................................................................7-4
7.4.4. Position of GEM80 Controller...............................................................................7-6
7.4.5. Access Requirements ..........................................................................................7-6
7.4.6. Heat Dissipation of I/O Modules..........................................................................7-7
7.4.7. Minimum Panel Spacings ....................................................................................7-7
7.4.8. Cable Routing and Segregation ........................................................................7-8
7.4.9. Pre-cut Ribbon Cable Lengths............................................................................7-8
7.5. Cabling GEM80.............................................................................................................7-9
7.5.1. Tools for Cabling...................................................................................................7-9
7.5.1.1. Ribbon Cables .............................................................................................7-9
7.5.2. Safety Earth Wiring...............................................................................................7-9
7.5.3. Signal Ground Wiring ...........................................................................................7-9
7.5.3.1. Signal Ground Bar........................................................................................7-9
7.5.3.2. GEM 80 0V..................................................................................................7-10
7.5.3.3. Screen Signal Grounds..............................................................................7-11
7.5.4. Wiring Segregation Within GEM 80 Cubicles....................................................7-11
7.5.5. Interconnecting GEM 80 ...................................................................................7-11
7.6. Plant Cabling External to GEM 80 Cubicles..............................................................7-11
7.6.1. General...............................................................................................................7-11
7.6.2. Segregation........................................................................................................7-12
7.6.2.1. General ......................................................................................................7-12
7.6.2.2. Basic and Verification I/O Ribbons ..........................................................7-12
7.6.2.3. Signal Ground............................................................................................7-12
7.6.2.4. Further Information on Plant Cabling.......................................................7-12
7.7. I/O Plant-Side Power Supply Connection.................................................................7-13
7.8. Installation of Modules................................................................................................7-13
7.8.1. Module Retention ..............................................................................................7-13
7.9. Address Decoder Switches and Address Marking...................................................7-14
7.9.1. Address Decoder Switches...............................................................................7-14
7.9.2. Address and Module Label Marking................................................................7-14
7.10. Ribbon Cable Connectors.......................................................................................7-15
8. Commissioning ......................................................................................................................8-1
8.1. Introduction...................................................................................................................8-1
8.2. Preparation....................................................................................................................8-1
8.3. Documents Required ...................................................................................................8-1
8.4. Overview of Commissioning Procedure .....................................................................8-2
8.5. Safety Circuits Checks..................................................................................................8-2
8.6. Power Module Checks.................................................................................................8-3
8.7. Processor Module Checks............................................................................................8-4
8.8. Central Highway Modules............................................................................................8-6
8.9. Loading an Initial User Program...................................................................................8-6
8.10. Basic and Verification I/O Logic Input Checks.........................................................8-6
8.11. Other Basic and Verification I/O Input Checks........................................................8-8
8.12. Fast I/O Input Checks .................................................................................................8-8
8.13. Basic, Verification and Fast I/O Output Checks.......................................................8-9
8.14. Connecting Output Equipment...............................................................................8-10
8.15. Loading the User Program .......................................................................................8-10
8.16. Serial Links..................................................................................................................8-10
8.16.1. Printer Ports .......................................................................................................8-11
8.16.2. Processor Serial Links Connecting Controllers................................................8-11
8.16.3. GEMSTART CCU Ports.......................................................................................8-12
8.16.4. Further Details...................................................................................................8-12
8.17. Fitting a Memory Expansion Board to the Processor Module ............................... 8-12
8.18. Processor Modules fitted with FIP Interface Facility ...............................................8-12
8.19. A Few Final Comments.............................................................................................8-13

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9. Maintenance and Fault Finding ...........................................................................................9-1
9.1. General..........................................................................................................................9-1
9.2. Spare Modules ..............................................................................................................9-1
9.3. Cleaning and Visual Inspection of GEM 80................................................................9-1
9.3.1. General Maintenance and Cleanliness.............................................................9-1
9.4. Batteries.........................................................................................................................9-2
9.4.1. General.................................................................................................................9-2
9.4.2. Battery Connection Procedure ..........................................................................9-2
9.4.3. Battery Replacement Procedure .......................................................................9-3
9.5. Fault Finding ..................................................................................................................9-3
9.5.1. Introduction..........................................................................................................9-3
9.5.2. Monitoring and Test Facilities ..............................................................................9-4
9.5.3. Indicators ..............................................................................................................9-5
9.5.3.1. Front Panel Indications................................................................................9-5
9.5.3.2. Display ..........................................................................................................9-5
9.6. User Program Checksum Calculations........................................................................9-5
9.7. Compilation and Compiler Error Messages (#100 to #199) .......................................9-5
9.7.1. Compilation Error Messages................................................................................9-5
9.7.2. Compilation Checks............................................................................................9-9
9.7.3. Error Messages #105 and #106 and I/O Scanning...........................................9-10
9.7.3.1. I/O Scanning..............................................................................................9-10
9.7.3.2. Basic and Verification I/O.........................................................................9-10
9.7.3.3. Fast I/O .......................................................................................................9-11
9.7.4. Programming Routine for Correction of Compilation Errors...........................9-11
9.7.5. Compilation Errors and the Controller..............................................................9-11
9.8. System Status at Power Up (#500 to #699)................................................................9-12
9.9. Self-test and Self-test Failure Error Messages (#700 to #799)....................................9-15
9.9.1. Self-test Error Messages (#700 to #799).............................................................9-15
9.9.2. Self-test System...................................................................................................9-17
9.9.2.1. Execution....................................................................................................9-17
9.9.2.2. Faults which immediately trip the watchdog.........................................9-17
9.9.2.3. Faults which trip the watchdog when detected by running tests........9-18
9.9.2.4. Faults from which recovery is automatic.................................................9-18
9.9.2.5. Faults which the user may program to trip the watchdog....................9-18
9.10. Interprocessor Communications (Error Messages #800 to #899)...........................9-18
9.11. System Errors (Error Messages #900 to #999) ........................................................... 9-18
9.12. F-Table Usage............................................................................................................9-20
9.13. Serial Communications Diagnostic F -Tables..........................................................9-21
9.13.1. Printer Port.........................................................................................................9-21
9.13.2. ESP Tributary Port..............................................................................................9-21
9.13.3. ESP Control Port................................................................................................9-21
9.13.4. GEMSTART CCU Port.........................................................................................9-22
9.14. Serial Communications Links Statistics F-Tables......................................................9-23
9.14.1. Printer Ports .......................................................................................................9-23
9.14.2. ESP Tributary Ports.............................................................................................9-23
9.14.3. ESP Control Ports...............................................................................................9-23
9.14.4. GEMSTART CCU Ports.......................................................................................9-24
9.15. I/O Statistics...............................................................................................................9-24
9.16. V-Data Tables............................................................................................................9-24
9.17. Clear Store Command.............................................................................................9-26
9.18. Power Module Self-test and Manual Test ...............................................................9-27
9.18.1. Self-test..............................................................................................................9-27
9.18.2. Manual test.......................................................................................................9-27
9.19. Intermittent Tripping Problems .................................................................................9-27
9.19.1. Electrical Noise or Electromagnetic Interference.........................................9-27