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

GEM80-500 Series Controller Contents
(08/04) GEM80-500 Technical Manual (T2025En) Page ix
6.3 Storing a GEM 80-500 Controller before Installation ........................................................... 6-2
6.3.1 Environmental Conditions and Protection............................................................................ 6-2
6.3.2 Capacitor Reforming ......................................................................................................... 6-2
6.4 Site Requirements .............................................................................................................. 6-2
6.5 Methods of Mounting......................................................................................................... 6-2
6.6 Panel Mounting the Controller............................................................................................ 6-3
6.6.1 Direct Mounting (without using a Panel Mounting Kit) .......................................................... 6-3
6.6.2 Using a 8890-4900 Panel Mounting Kit............................................................................. 6-3
6.7 Mounting the Controller in a Subrack ................................................................................. 6-4
6.8 Installation of Optional Modules......................................................................................... 6-6
6.8.1 Introduction....................................................................................................................... 6-6
6.8.2 Protection of Equipment from Static Damage ...................................................................... 6-6
6.8.3 Setting I/O, Serial Communications and GEMCAN I/O Module Jumper Links....................... 6-6
6.8.4 Setting FIP Module Subscriber Address................................................................................ 6-8
6.8.5 Installation of Optional Modules......................................................................................... 6-9
6.8.6 Connection of the 15 V Cable Assembly Referenced 41Y8230/10 ....................................... 6-9
6.8.7 Installation of an Optional Ethernet Module ...................................................................... 6-10
6.9 Supply and Earth/Ground Connections............................................................................. 6-11
6.10 Watchdog Relay Connections........................................................................................... 6-13
6.11 Connections for I/O Modules 9713-4020 and 9713-4021 ............................................... 6-14
6.12 Connections for Serial Communications Module 9714-4020............................................. 6-14
6.13 Termination of Serial Links ............................................................................................... 6-15
6.13.1 Termination of Serial Link when using RS485 .................................................................... 6-15
6.13.2 Maximum Length of Serial Links ....................................................................................... 6-15
6.13.3 Cable ............................................................................................................................. 6-15
6.13.4 Connectors ..................................................................................................................... 6-15
6.13.5 Segregation .................................................................................................................... 6-15
6.14 Commissioning Guidance................................................................................................ 6-15
6.14.1 Preparation .....................................................................................................................6-15
6.14.2 Documents Required........................................................................................................ 6-16
6.14.3 Handling Precautions During Setting Up of Equipment ...................................................... 6-16
6.14.4 Radio Frequency Interference (RFI).................................................................................... 6-16
6.15 Use and Setting of the Mode Switch.................................................................................. 6-17
6.15.1 Mode Switch Position 0 - Normal (A) ................................................................................ 6-17
6.15.2 Mode Switch Position 1 - Normal (B)................................................................................. 6-17
6.15.3 Mode Switch Position 2 – HALT......................................................................................... 6-17
6.15.4 Mode Switch Position 3 – Clear Store New System............................................................. 6-17
6.15.5 Mode Switch Position 4 – Firmware Update (FUP).............................................................. 6-18
6.15.6 Mode Switch Positions 5, 6, 7, 8 and 9 - Reserved............................................................. 6-18
6.16 Overview of the Commissioning Procedure....................................................................... 6-19
7. Maintenance and Fault Finding.......................................................................... 7-1
7.1 General Guidance for Maintenance ................................................................................... 7-1
7.2 Safety and Handling Information........................................................................................ 7-1
7.2.1 Earthing/Grounding .......................................................................................................... 7-1
7.2.2 High Voltages.................................................................................................................... 7-1
7.2.3 Power Down before Removing Modules or Connectors........................................................ 7-1
7.2.4 Power Down Safety Procedure............................................................................................ 7-1
7.2.5 On-line Programming........................................................................................................ 7-1
7.2.6 Testing a GEM80 System ................................................................................................... 7-2
7.2.7 Watchdog and Safety Circuits............................................................................................. 7-2
7.2.8 System Status Indication..................................................................................................... 7-2
7.3 Spare Modules .................................................................................................................. 7-2
7.4 Cleaning and Visual Inspection .......................................................................................... 7-2
7.5 Batteries............................................................................................................................ 7-3
7.6 Use of LED and Display Indicators ...................................................................................... 7-3
7.6.1 Controller Front Panel Indications....................................................................................... 7-3
7.6.2 Alphanumeric Status Display .............................................................................................. 7-3
7.6.3 System Status Indication..................................................................................................... 7-5

Contents GEM80-500 Series Controller
GEM80-500 Technical Manual (T2025En) (08/04)
Page x
7.7 Guidance for Fault Finding................................................................................................. 7-5
7.7.1 Introduction....................................................................................................................... 7-5
7.7.2 Monitoring and Test Facilities ............................................................................................. 7-6
7.8 User Program Checksum Calculations ................................................................................ 7-6
7.9 Compilation and Compiler Error Messages (#100 to #199)................................................ 7-7
7.9.1 Compilation Error Messages .............................................................................................. 7-7
7.9.2 Compilation Checks ........................................................................................................ 7-10
7.9.3 Error Message #105 and I/O Scanning............................................................................ 7-11
7.9.4 Programming Routine for Correction of Compilation Errors ............................................... 7-11
7.9.5 Compilation Errors and the Controller .............................................................................. 7-11
7.10 System Status at Power Up (#500 to #699) ...................................................................... 7-12
7.11 Self-test and Self-test Failure Error Messages (#700 to #799)............................................ 7-14
7.11.1 Self-test Error Messages (#700 to #799) .......................................................................... 7-14
7.11.2 Self-test System................................................................................................................7-16
7.12 Interprocessor Communications (Error Messages #800 to #899) ...................................... 7-17
7.13 System Errors (Error Messages #900 to #999).................................................................. 7-18
7.14 F-Table Usage................................................................................................................. 7-20
7.15 Serial Communications Diagnostics F-Tables .................................................................... 7-21
7.15.1 Printer Port ...................................................................................................................... 7-21
7.15.2 ESP Tributary Port ............................................................................................................ 7-21
7.15.3 ESP Control Port .............................................................................................................. 7-22
7.16 Serial Communications Statistics F-Tables ......................................................................... 7-23
7.16.1 Printer Ports..................................................................................................................... 7-23
7.16.2 ESP Tributary Ports ........................................................................................................... 7-24
7.16.3 ESP Control Ports............................................................................................................. 7-25
7.17 Verification & Basic I/O Statistics ...................................................................................... 7-25
7.18 V-Data Tables ................................................................................................................. 7-26
7.19 Clear Store Command..................................................................................................... 7-27
7.20 System Event Log ............................................................................................................. 7-28
7.21 Intermittent Tripping Problems.......................................................................................... 7-28
7.21.1 Electrical Noise or Electromagnetic Interference................................................................. 7-28
7.21.2 Connector/Termination Problems ..................................................................................... 7-29
7.21.3 Overheating.................................................................................................................... 7-29
7.22 Firmware Update............................................................................................................. 7-29
7.23 Repairs to GEM 80 Equipment.......................................................................................... 7-29
7.24 Fault Finding Back-up and Module Repair Service ............................................................. 7-29
7.25 Disposal.......................................................................................................................... 7-30
8. Upgrading GEM80 Systems................................................................................ 8-1
8.1 Upgrade Philosophy .......................................................................................................... 8-1
8.2 List of previous GEM80 systems which can be replaced by GEM80-500 ............................... 8-1
8.3 GEM80-500 Host Subrack Interface Module (9717-4020)................................................... 8-1
8.4 Guidance for upgrading an existing GEM80 System............................................................ 8-2
9. Re-Order Codes ................................................................................................. 9-1

GEM80-500 Series Controller Contents
(08/04) GEM80-500 Technical Manual (T2025En) Page xi
LIST OF FIGURES
Figure 1-1 Features of a GEM80-500 Controller.............................................................................1-2
Figure 1-2 9713-4020 Module for One Basic I/O and One Verification I/O Ribbon Cables..............1-3
Figure 1-3 9713-4021 Module for Two Basic I/O Ribbon Cables ....................................................1-3
Figure 1-4 9715-4020 FIP Module.................................................................................................1-4
Figure 1-5 9714-4020 Serial Communications Module...................................................................1-4
Figure 1-6 TCP/IP Ethernet Module ................................................................................................1-5
Figure 1-7 GEMCAN I/O Scanner Module......................................................................................1-5
Figure 3-1 9713-4020 1st Module Basic/Verification I/O Addressing and Linking ............................3-4
Figure 3-2 9713-4021 1st Module Basic/Basic I/O Addressing and Linking .....................................3-5
Figure 3-3 9713-4021 1st and 2nd Module Basic/Basic I/O Addressing and Linking .......................3-6
Figure 3-4 9713-4021 and 9713-4020 1st and 2nd Module Basic/Verification I/O Addressing and
Linking .........................................................................................................................3-7
Figure 3-5 9715-4020 FIP Port Identification and Address Configuration .........................................3-8
Figure 3-6 Serial Ports (Ports 1 to 4) Pinouts..................................................................................3-10
Figure 3-7 9714-4020 Serial Port Identification and Configuration................................................3-11
Figure 3-8 9720-4020 GEMCAN I/O Scanner Port Identification and Configuration ......................3-14
Figure 5-1 Programmer Port (Port 0) Pinouts...................................................................................5-2
Figure 6-1 Fixing Hole Dimensions for Direct Panel Mounting of a Controller...................................6-4
Figure 6-2 Fixing Hole Dimensions for Panel Mounting of a Controller using the 8890-4900 Mounting
Kit................................................................................................................................6-5
Figure 6-3 I/O and Serial Communications Modules showing Jumper Link Positions.........................6-7
Figure 6-4 GEMCAN I/O Scanner Module showing Jumper Link Positions........................................6-8
Figure 6-5 FIP Port Subscriber Address Configuration...............................................................6-8
Figure 6-6 Positions of 15 V Power Supply Connectors on I/O Modules and Controller Motherboard for
the 41Y8230/10 Cable Assembly................................................................................6-10
Figure 6-7 Typical Watchdog Circuit.............................................................................................6-14
Figure 7-1 Functions for GEM80-500 Controller Front Panel LED and Display Indicators ..................7-4
Figure 7-2 Symbols Displayed in Monitor Mode ..............................................................................7-6
Figure 8-1 Host Subrack Interface Module 9717-4020....................................................................8-2

Contents GEM80-500 Series Controller
GEM80-500 Technical Manual (T2025En) (08/04)
Page xii
LIST OF TABLES
Table 1-1 Optional Modules for GEM80-500 Controller ................................................................1-2
Table 3-1 Configuration Rules for Optional Modules......................................................................3-3
Table 3-2 P-Tables reserved for GEM80-500 FIP ...........................................................................3-9
Table 3-3 Data Tables for Serial Ports 1 to 4 ...............................................................................3-12
Table 3-4 P-Tables for Printer/Keyboard Port ...............................................................................3-13
Table 3-5 P-Table reserved for GEM80-500 GEMCAN I/O Scanner .............................................3-15
Table 4-1 Data Tables for Serial Ports 1 to 4 .................................................................................4-1
Table 4-2 Configuring a Printer Port: P-table data..........................................................................4-3
Table 4-3 Configuring an ESP Tributary Port: P-table data..............................................................4-6
Table 4-4 Configuring an ESP Tributary Port: J, K and I-table data..................................................4-6
Table 4-5 Configuring an ESP Control Port....................................................................................4-7
Table 4-6 J - and K-Tables for an ESP Control Port ........................................................................4-7
Table 4-7 I-Table for an ESP Control Port ......................................................................................4-8
Table 4-8 Configuring an ESP Control Port using Flexible Data Tables ............................................4-9
Table 4-9 Route Assignment for J- and K-Tables ..........................................................................4-10
Table 4-10 I-Table for an ESP Control Port using Flexible Data Tables ............................................4-10
Table 5-1 Pin functions for Programmer Port (Port 0)......................................................................5-2
Table 5-2 GEM80-500 Controller Instruction Set ...........................................................................5-6
Table 5-3 GEM80 Instructions NOT IN the GEM80-500 Controller...............................................5-12
Table 5-4 Storage Locations when the system is running in EPROM...............................................5-13
Table 5-5 GEM80-500 Data Tables ............................................................................................5-18
Table 5-6 P-Table Contents ........................................................................................................5-22
Table 5-7 E-Table Contents ........................................................................................................5-23
Table 5-8 F-Table Contents ........................................................................................................5-24
Table 5-9 I-Table Content...........................................................................................................5-26
Table 5-10 J/K-Table Content.......................................................................................................5-26
Table 5-11 V-Table Content..........................................................................................................5-27
Table 6-1 I/O and Serial Communications Module Jumper Links....................................................6-7
Table 7-1 Error Messages .............................................................................................................7-6
Table 7-2 Compilation Error Messages..........................................................................................7-7
Table 7-3 System Status Error Messages ......................................................................................7-12
Table 7-4 Self-test Error Messages ..............................................................................................7-14
Table 7-5 Interprocessor Communications Error Messages...........................................................7-17
Table 7-6 System Error Messages................................................................................................7-18
Table 7-7 F-Table Contents ........................................................................................................7-20
Table 7-8 ESP Tributary Port F-Tables ..........................................................................................7-21
Table 7-9 ESP Control Port F-Tables ............................................................................................7-22
Table 7-10 ESP Tributary Port Link Statistics ...................................................................................7-24
Table 7-11 ESP Control Port Link Statistics .....................................................................................7-25
Table 7-12 V-Table ......................................................................................................................7-26
Table 8-1 GEM80 Upgrading Recommendations...........................................................................8-3

GEM80-500 Series Controller 1. Introduction
(08/04) GEM80-500 Technical Manual (T2025En) Page 1-1
1. Introduction
1.1 The GEM80-500 Series Controller
1.1.1 Overview
The GEM80-500 Series Controller is similar in power and flexibility to a GEM80-400
Controller but housed in a much smaller enclosure. It is suitable for new applications
and for upgrading existing GEM80 Systems (refer to Section 8 for upgrading
information).
The GEM80-500 Controller has many of the facilities of the GEM80-400 Controller
including:
(a) Serial Links;
(b) Real Time Clock;
(c) RAM/Flash EPROM Storage;
(d) Basic and Verification I/O.
Section 1 of this manual provides an overview of the product and its features.
Section 2 of this manual includes a System Specification (2.5) which outlines the
compatibility with the GEM80 range of products and details those system features
particular to the GEM80-500 Controller.
1.1.2 Compatibility with other GEM80 Products
The GEM80-500 Controller is compatible with other GEM80 products including:
(a) All Basic I/O Modules;
(b) All Verification I/O Modules;
(c) Verification I/O Expanders;
(d) Verification Remote I/O;
(e) All variants of ESP;
(f) User Program and GEM80 Ladder Diagram Programming Language.
Notes:
(1) The GEM80-500 Controller does not support GEMSTART CCU, Fast I/O Modules,
GEMLAN-D, STARNET, or an IMAGEM Graphics Display Module.
(2) There are also some differences in the GEM80-500 Controller Instruction Set,
compared to other GEM80 products, including no support for floating point
operation and a reduced range of Maths Functions. Refer to Table 5-2 and
Table 5-3 where the full set and the differences are detailed.

1. Introduction GEM80-500 Series Controller
GEM80-500 Technical Manual (T2025En) (08/04)
Page 1-2
1.2 Features
The GEM80-500 Series Controller is shown at Figure 1-1 with its features annotated.
Each of the features is described at an appropriate place within the manual. The
controller is a compact unit with an integral power supply. It is supplied for either
panel mounting or subrack mounting to meet the requirements of new applications and
those for upgrading existing GEM80 Systems. The controller also has a facility for
optional modules to be added for additional applications. The optional modules are
described at 1.3.
GEM80
500
Ethernet Connector
Facilities for panel
mounting (optional)
IEC Connector with
y ON/OFF switch
y Supply Connector
y HRC Fuse 5 x 20 mm
Watchdog Connector
Optional Modules Handle
Mode Selector Switch
Status Display
Watchdogs 'Healthy' Indicators
Ethernet Rx Tx LEDs
Ethernet Active LED
Battery Low LED
Programming Rx Tx LEDs
Front Accessible
Connections
Programming Port
Subrack Mounting Guide
Figure 1-1 Features of a GEM80-500 Controller
1.3 Optional Modules
The GEM80-500 Controller is available with a range of optional modules for
connection to I/O Highways and external communications. These optional modules
are listed at Table 1-1 and the facilities are now described.
Table 1-1 Optional Modules for GEM80-500 Controller
ALSTOM
Reference
Description Remarks
9713-4020 Basic plus Verification I/O Interface A maximum of 1 per system
9713-4021 Basic I/O Interface A maximum of 2 per system
9714-4020 Serial Communications Module (RS232/RS485) A maximum of 2 per system
9715-4020 FIP Module (1 Mbits/s) A maximum of 1 per system
9716-4020 TCP/IP Ethernet Module A maximum of 1 per system
9720-4020 GEMCAN I/O Scanner Module A maximum of 2 per system

GEM80-500 Series Controller 1. Introduction
(08/04) GEM80-500 Technical Manual (T2025En) Page 1-3
1.3.1 9713-4020 Basic and Verification I/O Interface Module
Board Number
LED
Basic I/O Ribbon
Connector
(256 bits)
Verification I/O
Ribbon Connector
(1024 words)
15 V Power Supply
Connector for
Cable Assembly
41Y8230/10
Board Selector
Jumper Link
(see 6.8.3)
Figure 1-2 9713-4020 Module for One Basic I/O and One Verification I/O Ribbon Cables
The Module has connection facilities for one Basic I/O Ribbon Cable of 256 bits
capacity and one Verification I/O Ribbon Cable of 1024 Words capacity.
1.3.2 9713-4021 Basic I/O Interface Module
15 V Power Supply
Connector for
Cable Assembly
41Y8230/10
Board Number
LED
Basic I/O Ribbon
Connector
(256 bits)
Basic I/O Ribbon
Connector
(256 bits)
Board Selector
Jumper Link
(see 6.8.3)
Figure 1-3 9713-4021 Module for Two Basic I/O Ribbon Cables
The Module has connection facilities for two Basic I/O Ribbon Cables each of 256 bits
capacity.

1. Introduction GEM80-500 Series Controller
GEM80-500 Technical Manual (T2025En) (08/04)
Page 1-4
1.3.3 9715-4020 FIP (Factory Instrumentation Protocol) Module
A FIP Module for use with the GEM80-500 Controller will provide the technology to
transfer data on a FIP (Factory Instrumentation Protocol) Network. The module is one
of the optional modules for use with the controller. Refer to the T1653 GEM80 Series
Controllers FIP Technical Manual for full details about use with the GEM80-500
Controller.
Network Subscriber
Address
BCD Switches
(see 6.8.4)
9-Way 'D' Type
Connectors
Figure 1-4 9715-4020 FIP Module
1.3.4 9714-4020 Serial Communications Module
Board Number
LED
Board Selector
Jumper Link
(see 6.8.3)
9-Way 'D' Type
Connectors
Figure 1-5 9714-4020 Serial Communications Module
The Module provides two isolated RS232/RS485 communication ports. Each port can
support:
• GEM80 Standard ESP;
• Programming;
• Printer.

GEM80-500 Series Controller 1. Introduction
(08/04) GEM80-500 Technical Manual (T2025En) Page 1-5
1.3.5 9716-4020 TCP/IP Ethernet Module
Figure 1-6 TCP/IP Ethernet Module
The Module can support:
• Up to 50 virtual simultaneous connections;
• Programming connection available using AGP (Advanced GEM80
Programmer);
• Peerless Communications;
• Built-in Web Server.
1.3.6 9720-4020 GEMCAN I/O Scanner Module
Board Number
LED
Board Selector
Jumper Link
(see 6.8.3)
Firmware Update
Mode Pushbutton
CAN Tx / Rx LED
Indication
Firmware Update
Serial Port
CAN Port 'A/C' CAN Port 'B/D'
Figure 1-7 GEMCAN I/O Scanner Module
The Module provides two CAN communications ports, CAN ‘A’ and ‘B’. Each port can
support:
• Communications to I/O
• Communications to other GEM80 controllers

1. Introduction GEM80-500 Series Controller
GEM80-500 Technical Manual (T2025En) (08/04)
Page 1-6
1.4 Associated Publications
ALSTOM Publications associated with this technical manual are now listed.
T391 GEM80 Ladder Diagram Language Programming Manual
This manual provides a competent user, who is familiar with
programming GEM80 controllers, details for all aspects of programming,
including the language, the Standard Instruction Set and all the GEM80
Special Functions. It does not include some Additional Instructions which
are used for the GEM80-400 and 500 Series Controllers that are
described in the GEM80-400 manual.
T1614 GEM80-400 Series Controllers Technical Manual
This manual provides a competent user who is familiar with GEM80
controllers details for the installation, commissioning, operation and
maintenance of the GEM80-400 Series Controllers. It includes some
software details which are cross-referenced from the GEM80-500
manual.
T1653 GEM80 Series Controllers FIP Technical Manual
This manual provides a competent user who is familiar with GEM80
controllers details for the specification, configuration, installation and
operation of a FIP Module for use with a GEM80-400/500 Controller.
Note:
The FIP Module used with the GEM80-500 Controller has some
differences from that used for the GEM80-400 Controller (e.g. in the
P-tables where P94 to P96 were P120 to P122 for GEM80-400).
However, much of the information in the T1653 Manual will be of use
with the GEM80-500 Controller.
T2011 GEMLAN-T Technical Manual
This manual provides the information necessary to configure and install
the GEMLAN-T Module for communications between networked GEM80
Controllers. The manual covers the module’s technical and physical
specifications, installation, operation and general use. Examples and
application notes are also included.
T457 GEM80 Serial Communications Technical Manual
This manual provides comprehensive technical information about GEM80
serial links. It includes guidance for the construction and operation of
serial links between GEM80 Controllers and between GEM80 equipment
and other types of equipment.
T2031En GEM80 GEMTEQ I/O Technical Manual
This manual provides a competent user details for the specificaion,
configuration, installation and operation of a GEMTEQ I/O system for use
with GEM80.