Alstom GEM80-500 Series User manual

GEM80-500
Series Controllers
Technical Manual
Publication No. T2025En
Issue 3 (08/04)
ABCD

GEM80-500
Series Controllers
Technical Manual
Publication No. T2025En
Issue 3 (08/04)

Issue Information GEM80-500 Series Controller
GEM80-500 Technical Manual (T2025En) (08/04)
Page ii
Acknowledgements
Ethernet is a trademark of Xerox Corporation
Issue Information
Publication T2025En Issue 3 (08/04) Addition of GEMCAN I/O Scanner
Module and dc power supply versions.
New System Status Indications.
Publication T2025En Issue 2 (11/02) Addition of FIP Module.
Publication T2025En Issue 1 (08/02) Initial Release.
Manufacturer
ALSTOM Power Conversion Ltd.
West Avenue,
Kidsgrove,
Stoke-on-Trent,
Staffs.,
ST7 1TW
England.
Tel: [phone]
Fax: [phone]
e-mail: [email protected]
© - ALSTOM - 2004. ALSTOM, the logo ALSTOM and their frameworks are
trademarks and service trademark applications of ALSTOM. The other names
mentioned, registered or not, are the property of their respective companies.

GEM80-500 Series Controller Safety
(08/04) GEM80-500 Technical Manual (T2025En) Page iii
SAFETY INSTRUCTIONS
Care has been taken with the design of this product to ensure that it is safe. However,
in common with all products of this type, misuse can result in injury or death.
Therefore, it is very important that the instructions in this manual and on the product
are observed during transportation, commissioning, operation, maintenance and
disposal.
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.
Local safety laws and regulations must always be observed.
Persons working on the product must be suitably skilled and should have been trained
in that work for these products.
The product is a component designed for incorporation in installations, apparatus and
machines.
The product must not be used as a single item safety system. In applications where
maloperation of the product could cause danger, additional means must be used to
prevent danger to persons.
Product approvals and certifications will be invalidated if the product is transported,
used or stored outside its ratings or if the instructions in this manual are not observed.
In the European Union:
Products within the scope of the Low Voltage Directive, 73/23/EEC as amended are CE
marked.
The product complies with the essential protection requirements of the EMC directive
89/336/EEC as amended, when installed and used as described in this manual. The
requirements of the EMC Directive should be established before any installation,
apparatus or machine which incorporates the product is taken into service.
A machine should not be taken into service until the machine has been declared in
conformity with the provisions of the Machinery (Safety) Directive, 98/37/EEC.

Safety GEM80-500 Series Controller
GEM80-500 Technical Manual (T2025En) (08/04)
Page iv
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GEM80-500 Series Controller Scope
(08/04) GEM80-500 Technical Manual (T2025En) Page v
Scope
This publication provides details of the GEM80-500 Series Controller which is a new
GEM80 Controller similar in power and flexibility to a GEM80-400 Controller but
housed in a much smaller enclosure. An overview of the product and its features and
specification are included in this publication as well as details to enable system
Configuration, Programming, Installation and Commissioning, Maintenance and Fault
Finding to be carried out.
The GEM80-500 Series Controller is designed for upgrading existing GEM80 Systems,
and for new applications, and this publication includes guidance for carrying out such
upgrades.
Because of the similarity between the GEM80-500 and GEM80-400 Series Controllers,
and the commonality of many of their features, this publication will often refer to details
which can be found in the GEM80-400 Publication T1614 and should therefore be
read in conjunction with it. This publication (T2025En) should be regarded as part of
the GEM80-500 product. It should be retained for the life of the product and passed
on to any subsequent owner or user.

Scope GEM80-500 Series Controller
GEM80-500 Technical Manual (T2025En) (08/04)
Page vi
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GEM80-500 Series Controller Contents
(08/04) GEM80-500 Technical Manual (T2025En) Page vii
CONTENTS
Section Page
Acknowledgements.................................................................................................... ii
Issue Information....................................................................................................... ii
Safety Instructions ...................................................................................................... iii
Scope ........................................................................................................................ v
Contents ...................................................................................................................vii
1. Introduction........................................................................................................ 1-1
1.1 The GEM80-500 Series Controller...................................................................................... 1-1
1.1.1 Overview .......................................................................................................................... 1-1
1.1.2 Compatibility with other GEM80 Products ........................................................................... 1-1
1.2 Features............................................................................................................................ 1-2
1.3 Optional Modules.............................................................................................................. 1-2
1.3.1 9713-4020 Basic and Verification I/O Interface Module...................................................... 1-3
1.3.2 9713-4021 Basic I/O Interface Module .............................................................................. 1-3
1.3.3 9715-4020 FIP (Factory Instrumentation Protocol) Module................................................... 1-4
1.3.4 9714-4020 Serial Communications Module ....................................................................... 1-4
1.3.5 9716-4020 TCP/IP Ethernet Module................................................................................... 1-5
1.3.6 9720-4020 GEMCAN I/O Scanner Module........................................................................ 1-5
1.4 Associated Publications ...................................................................................................... 1-6
2. Specification....................................................................................................... 2-1
2.1 Introduction....................................................................................................................... 2-1
2.2 Environmental Specification ............................................................................................... 2-1
2.3 Mechanical Specification.................................................................................................... 2-1
2.4 Electrical Specification........................................................................................................2-2
2.5 System Specification........................................................................................................... 2-4
3. Configuration of Optional Modules.................................................................... 3-1
3.1 Introduction....................................................................................................................... 3-1
3.2 Configuration of Optional Modules in the controller............................................................ 3-1
3.2.1 Configuration Rules ........................................................................................................... 3-1
3.2.2 Configuration Recommendations ....................................................................................... 3-2
3.2.3 Recommended Module Stacking Arrangement .................................................................... 3-2
3.3 Using one 9713-4020 Basic and Verification I/O Interface Module...................................... 3-4
3.3.1 I/O Access (Capacity and Addressing) ................................................................................ 3-4
3.4 Using one 9713-4021 Basic I/O Interface Module .............................................................. 3-5
3.4.1 I/O Access (Capacity and Addressing) ................................................................................ 3-5
3.5 Using two 9713-4021 Basic I/O Interface Modules ............................................................. 3-6
3.5.1 I/O Access (Capacity and Addressing) ................................................................................ 3-6
3.6 Using one 9713-4020 and one 9713-4021 I/O Interface Modules ..................................... 3-7
3.6.1 I/O Access (Capacity and Addressing) ................................................................................ 3-7
3.6.2 Basic I/O Expansion .......................................................................................................... 3-8
3.7 FIP Module 9715-4020 ..................................................................................................... 3-8
3.7.1 FIP Connection ..................................................................................................................3-9
3.8 Serial Communications Module 9714-4020 ..................................................................... 3-10
3.8.1 Serial Ports 1 to 4 Pin Connections ................................................................................... 3-10
3.8.2 Configuring the Serial Ports.............................................................................................. 3-12
3.8.3 Data Tables.....................................................................................................................3-12
3.8.4 Installation ...................................................................................................................... 3-13
3.9 TCP/IP Ethernet Module 9716-4020................................................................................. 3-13
3.9.1 Ethernet Connection ........................................................................................................ 3-13
3.10 GEMCAN I/O Scanner Module 9720-4020...................................................................... 3-14

Contents GEM80-500 Series Controller
GEM80-500 Technical Manual (T2025En) (08/04)
Page viii
4. Serial Communications ...................................................................................... 4-1
4.1 Applications of Serial Communication Links ........................................................................ 4-1
4.2 Data Tables....................................................................................................................... 4-1
4.3 Communication between GEM80 Controllers...................................................................... 4-2
4.4 Operation as a Printer/Keyboard Port................................................................................. 4-3
4.4.1 Direct Mode ...................................................................................................................... 4-3
4.4.2 Terminal Mode.................................................................................................................. 4-4
4.4.3 Free Format Mode............................................................................................................. 4-5
4.5 Serial communications between two or more GEM80 Controllers (ESP Protocol) ................... 4-6
4.5.1 Operation as an ESP Tributary Port..................................................................................... 4-6
4.5.2 Operation as an ESP Control Port....................................................................................... 4-7
4.5.3 Operation as an ESP Control Port with Flexible Data Tables................................................. 4-9
4.5.4 Operation as a Control Port............................................................................................. 4-12
5. Programming .....................................................................................................5-1
5.1 Introduction....................................................................................................................... 5-1
5.2 Programming .................................................................................................................... 5-1
5.2.1 Programmer Units and Tools.............................................................................................. 5-1
5.2.2 Remote Programming ........................................................................................................ 5-1
5.2.3 Program and Data Table Capacity ..................................................................................... 5-1
5.2.4 Message Editing Facility ..................................................................................................... 5-1
5.2.5 Connecting a Suitable GEM 80 Programming Tool.............................................................. 5-2
5.2.6 Programming Port (Port 0) Connections .............................................................................. 5-2
5.2.7 Program Compilation ........................................................................................................ 5-3
5.2.8 On-line Program Changes................................................................................................. 5-3
5.2.9 Off-line Program Debugging.............................................................................................. 5-4
5.2.10 Loading Programs ............................................................................................................. 5-4
5.2.11 Programming the Controller............................................................................................... 5-5
5.3 User Program....................................................................................................................5-5
5.3.1 Introduction....................................................................................................................... 5-5
5.3.2 GEM80-500 Controller Instruction Set ................................................................................ 5-5
5.4 Differences between the GEM80-400 and GEM80-500 Instruction Sets.............................. 5-11
5.5 Programming Procedures................................................................................................. 5-11
5.5.1 Declare Highest Address .................................................................................................. 5-11
5.5.2 Storing Programs............................................................................................................. 5-11
5.5.3 Storing Program and Presets in Flash EPROM.................................................................... 5-13
5.5.4 Transferring Program and Presets to Flash EPROM ............................................................ 5-13
5.5.5 Programming Flash EPROM ............................................................................................. 5-14
5.6 Watchdog Trip Initiated by User Program.......................................................................... 5-15
5.7 Data Tables.....................................................................................................................5-15
5.7.1 Data Table Addressing..................................................................................................... 5-15
5.7.2 Data Storage Formats...................................................................................................... 5-16
5.7.3 Data Table Content and Addresses................................................................................... 5-16
5.7.4 Data Table Sizes.............................................................................................................. 5-17
5.7.5 Action of Clear Store on Data Tables ................................................................................ 5-17
5.7.6 P-Tables.......................................................................................................................... 5-21
5.7.7 E-Tables.......................................................................................................................... 5-23
5.7.8 F-Tables.......................................................................................................................... 5-24
5.8 Fault Reporting and Detection .......................................................................................... 5-25
5.8.1 I-Tables........................................................................................................................... 5-26
5.8.2 J/K-Tables....................................................................................................................... 5-26
5.8.3 R-Tables.......................................................................................................................... 5-26
5.8.4 V-Tables.......................................................................................................................... 5-26
6. Installation and Commissioning .........................................................................6-1
6.1 Introduction....................................................................................................................... 6-1
6.2 Receipt of a GEM80-500 Controller ................................................................................... 6-1
6.2.1 Unpacking and Checking the Consignment ........................................................................ 6-1
6.2.2 What to do if something is missing or damaged.................................................................. 6-2