Gemini 4100 User manual

THE ASTRO LINE SERIES
GEMINI 4000 INSTRUCTION MANUAL
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INTRODUCTION
The Gemini 4100 and 4200 are both units in a multi-purpose series of
industrial control units that are field-programmable to solve multiple
applications. This series, known as the Astro-Line family of products, is built
around the concept that the end user has the capability to program different
personalities and functions into the unit in order to adapt to different indication
and control requirements.
The Gemini, which you have purchased, has the same high quality
workmanship and advanced technological capabilities that have made Red Lion
Controls the leader in today's industrial market.
Red Lion Controls has a complete line of industrial indication and control
equipment, and we look forward to being of service to you now and in the future.
CAUTION: Risk of Danger.
Read complete instructions prior to
installation and operation of the unit.
CAUTION: Risk of electric shock.
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TABLE OF CONTENTS
I. GENERAL DESCRIPTION 2
A) Safety Summary 2
B) Programming The Gemini 3
C) Programming The Personality 3
D) Programming The Presets, Scale Factors, Timed Outputs & Counter Load Values 3-5
E) Initial Factory Configuration Counter/Rate & Dual Counter Factory Settings 6
F) Operator Accessible Functions With Programming Disabled 7
G) Diagnostics, Self-Test, & “Watchdog” Timer 7-8
H) Input Circuitry & Set-up 8
I) Overflow Indication 8
II. PROGRAMMING INSTRUCTIONS FOR THE COUNTER/RATE VERSION OF THE GEMINI 9
A) Codes 41, 42, 43, 44, 45, & 46, 51, 52, 53, 54, 55, & 56 9-14
B) Codes 61, 62, 63, 64, 65, 66, Preset Values, Scale FactorsA&B,Counter Load Value 15-17
C) Dual Preset Counter & Rate Application 18-19
III. PROGRAMMING INSTRUCTIONS FOR THE DUAL COUNTER VERSION OF THE GEMINI 20
A) Codes 41, 42, 43, 44, 45, & 46 20-22
B) Codes 51, 52, 53, 54, 55, & 56 22-25
C) Codes 61, 64, 65, 66, Preset Values, Scale FactorsA&B,Counter Load Values 25-27
E) Dual Counter Batching Application 28-29
IV. 20 MA CURRENT LOOP COMMUNICATIONS 30
A) Communication Format 30
B) Sending Commands & Data To The Gemini 30-32
C) Receiving Data From The Gemini 32
D) Print Options 33
E) Current Loop Installation 34
F) Communications Application 35
G) Troubleshooting Gemini Serial Communications & Serial Loop-Back Self-Test 36
V. APPENDIX “A” - INSTALLATION & INPUT CONFIGURATION SWITCH SET-UP 37-45
VI. APPENDIX “B” - SPECIFICATIONS & DIMENSIONS 46-47
VII. APPENDIX “C” - TROUBLESHOOTING GUIDE 48-49
VIII. APPENDIX “D” - COUNTER/RATE & DUAL COUNTER MODE FUNCTION COMMAND CODE SUMMARY 50-57
IX. APPENDIX “E” - SCALING FOR COUNTING 58-59
X. APPENDIX “F” - SCALING FOR RATE 60-61
XI. APPENDIX “G” - GEMINI 4100 PROGRAMMING CHARTS 62-64
XII. APPENDIX “H” - GEMINI 4200 PROGRAMMING CHARTS 65-69
XIII. APPENDIX “I” - ORDERING INFORMATION 70
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GENERAL DESCRIPTION
The Gemini 4000 series (4100 & 4200) instruments are two input
microprocessor based dual function counter/rate or dual counter instruments.
The 6-digit display features 0.56" high LEDs with negative sign, overflow and
displayed value indicators (A & B) located to the left of the display. When
programmedasacounter/rateinstrument,theAindicatorwillbeonwhentherate
is displayed and the B indicator will be on when the count is being displayed.
Pushing the “+/-” button toggles the display between the counter and rate or the
two counters depending on the personality selected.
TheGemini4000series consistsoftwobasic units,asingle presetversion,the
Gemini 4100, and a two preset version, the Gemini 4200. Each basic unit is also
availablein115/230VACversions,withorwithoutSerialcommunicationsanda
relay board. The 20 mA current loop option (serial communications) makes
possible remote or computerized monitoring or control of the Count, Presets and
Scale Factors.
Flexibility and usefulness are insured through user programmability. With
simplefrontpanel keystrokesand rearpanelswitch settings,anyoneofa number
of configurations can be selected. Once the selection is made, all or part of the
keyboard can be disabled to protect the settings and guarantee that no unwanted
changes can occur during the measurements.
Eachtimethepower isturnedoff, theunitautomaticallysavesthe settingsand
data in its special no power memory. When power is restored, the Gemini sets
itself back to the operational modes and restores the data it had at power down.
The “no power” E2PROM’s life expectancy is at least 100,000 cycles of power
being applied to and removed from the unit.
Whenever the power comes on, the Gemini performs a series of internal
diagnosticsto verifytheintegrity ofthestored data.Thereis alsoaself-testmode
and a “watchdog” timer to help prevent processor lockup.
The Gemini 4000 series counters can accept bi-directional, uni-directional, or
quadrature signals. They also have the capability to double or quadruple
(Quadrature x4) the resolution of the incoming count signal. A separate input
mode is available to make the counter/rate or dual counters completely
independent of each other.
Oneinputprovides the signalforrateor a counterandthe other inputprovides
the signal for a counter. An anti-coincidence add/subtract mode is also provided
to obtain a difference between two input signals.
Each channel features separate scaling and decimal point placement for
readout in different units or at different resolutions.
A Counter Load feature enables the operator to modifythe count value under
circumstances that occur when flawed material has been counted and it is
necessarytoadjustthecountvalueaccordingly.TheCounterLoad featurecan be
“locked out” in applications where it is not required.
The Rate Indicator portion uses a time interval method (1/tau) to calculate the
rate value. This method enables high resolution at all rates. The unit counts input
pulses and after a programmable minimum update time has occurred, it waits
until the next edge occurs, takes the elapsed time and number of edges, and
calculates the rate value. At slower rates, averaging can be accomplished by
programming the “Rate Minimum Update Time” (0.5 sec. to 16 sec.) for the
desired response. Extensive scaling capabilities allow practically any desired
reading at very slow count rates.
For maximum flexibility, the Gemini’s output(s) can be assigned to either the
rate or count channels or one to each. When in dual counter mode, the output(s)
can be assigned to the Counter B channel. For the Gemini 4200, one can be
assigned to Counter A and the other to Counter B.
The relay(s) are mounted on a plug-in board which makes it easy to field
upgradeyourGemini.Thecontactsareratedfor240VACor28VDCat5amps.
The construction of the Gemini features a metal, die cast bezel for maximum
durability with high quality appearance. The sealed front panel meets NEMA
4/IP65 specifications for washdown and/or dust, when properly installed.
Electrical connections are made with removable, plug-in terminal strips at the
rear of the unit. Clamp-type pressure plate terminals accept stripped #14 AWG
wire without lugs.
SAFETY SUMMARY
All safety related regulations, local codes and instructions that appear in the
manual or on equipment must be observed to ensure personal safety and to
prevent damage to either the instrument or equipment connected to it. If
equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
Donotuse this unit todirectlycommandmotors,valves, or otheractuatorsnot
equipped with safeguards. To do so, can be potentially harmful to persons or
equipment in the event of a fault to the unit.
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PROGRAMMING THE GEMINI
When your Gemini arrives from the factory, it has already been programmed
to function as a counter and rate indicator. It is programmed with the factory
settings listed in the “Initial Factory Configuration” section. If it is required to
have the unit operate as two counters, the Unit Personality function code can be
changedtodoso.
The personality, functions, and modes are accessed by pressing the appropriate
keys.Afunctionisdefined bya two-digitcodewhichappearson theleftside ofthe
display. The mode of that function is shown as a one-digitcode on the right side of
the display. At times there will be a “-” sign modifier to the left of the mode.
Data for the Presets, Scale Factors, Timed Output Values, and Counter Load
Values are entered differently. Each digit key controls the digit on the display
directly above it. Changing the digits can be done by repeatedly pressing the key
beneaththe digitposition youwishto changeor byholding thekeydown.Asyou
holdit down,orrepetitively pressit,the valueofthat digitwillchange cyclically,
countingupto9,thento0,andthenupagain.The6numberedkeyscorrespondto
the six digits, and the “+/-” key corresponds to polarity.
PROGRAMMING THE PERSONALITY
Entering function and mode is easily accomplished by
pressingthe appropriatedigit key.Forthepersonalityfunction,
you would enter 41 by pressing the front panel keys 4 and 1.
Thedigits on theleftside of thedisplay showthefunction
code; the digits on the right side show the current
programmed mode.
A mode selection is made by entering a new number. On
some of the entries, you have the option of a plus “+” or minus
“-” sign. In the cases where a “+” sign is required, no sign will
be displayed. If you do enter a “-” sign (using the “+/-” key), a
minus sign will be displayed in front of the appropriate digit.
Pressing the “E” key finalizes the change. The display
will now show the count or rate value immediately.
If you do not press the “E” key, the change will not be
recorded.Thedisplay will remainin the programmingmode
for 15 seconds, and then return to normal operating mode
using the old functional mode setting.
Whenever the Unit Personality is changed, the factory settings will
automatically be loaded into the unit. The factory settings can also be
programmedinto theunitbycalling up theUnitPersonality, puttinga“-”in front
of the mode by pushing the “+/-” button, and entering it.
Refer to the “Initial Factory Configuration” section for more details.
PROGRAMMING THE PRESET, SCALE FACTORS, TIMED
OUTPUTS & COUNTER LOAD VALUES
The Presets and Scale Factor Values are commonly reprogrammed on a daily
basis. As such, single keystroke access has been provided.
The Gemini has two Scale Factors, one for display A
(Counter A or Rate A), and one for display B (Counter B).
Pressing the “3” key will call up the Scale Factor for the
current display (Rate A/Counter A, or Counter B).
To call up the “other” Scale Factor, the “+/-” key is first pushed to change the
displaytothe“other”value,thenthe“3”keyispushedto displaytheScaleFactor
for that value.
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PROGRAMMING THE PRESET, SCALE FACTORS, TIMED
OUTPUTS & COUNTER LOAD VALUES (Cont’d)
Once the Scale Factor is displayed, changing the digits
canbeaccomplishedby repeatedly pressing the key beneath
the digit position you wish to change or by holding the key
down, allowing the digit to cycle.
The new value will be entered when the “E” key is
pressed.
The internal count value is multiplied by the Scale Factor Value, which
changesthe displayed valueaccordingly.It isimportanttonotethat theprecision
ofanapplicationcannotbeimprovedbyusing aScaleFactorgreaterthanone.To
accomplish greater precision, more pulse information must be generated per
measuring unit. For example, if 5 pulses are being received per foot of material,
the precision of 10th of feet cannot be attained by simply programming a Scale
Factor of 2.0000, even though the display is reading in tenths. In this case, the
display will increment by two for each count input. Thus, if an odd Preset Value
is entered, such as 6.7 ft., the Gemini will alter the Preset display to read in even
tenths of feet.
To display the Preset 1 Value the “1” key is pushed.
To change the value, the digits can be cycled through in
the same manner as discussed for the Scale Factor. The
preset values can range from -999999 to +999999.
The new value will be entered when the “E” key is
pressed.
The Scale Factor Value will have a direct effect on the preset being entered (if
assigned to the counter). For Scale Factors greater than one, the preset value
should be an integer multiple of the Scale Factor. If it is not, the Gemini will
automatically adjust the preset value up or down to force it to be evenly divisible
by the Scale Factor.
The Timed Output 1 or 2 Value is changed by entering a
two-digit function code. After the code is entered, the
display will show the present Timed Output Value in
seconds with two decimal place resolution. The Timed
Output Values can be set from .01 to 599.99 seconds.
Tochange the TimedOutput 1 Value,enterfunction code
53 and enter the new value by holding down or repeatedly
pressingthekeybelowthedigitpositionyouwishtochange.
The new value will be entered when the “E” key is pressed.
The display will immediately return to the count value.
Note: A Timed Output Value of zero cannot be programmed into the Gemini. If a
value of 0 is entered into the display and the “E” key is pressed, the unit will
remain in data entry mode. If a new value is not entered, it will time out and the
unit will continue to use its previous setting.
As with the other functions, you must press “E” to record the changes. For the
data entry modes, if you do not press the “E” key,a time out of 5 seconds occurs,
and the display returns to operating mode without anychanges to the value. The
only time any change will occur is when the “E” key is pressed.
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It is possible to change the counter values of the Gemini. This feature can be
enabled or disabled by the programming of the “Operator Accessible Functions
Modes”,function code66.The“CounterLoad Value”isnot storedwhen theunit
ispowered down. Whentheunit is poweredup,the CounterLoadvalues for both
counters(ifDualcounter personality) are resettozero.Oncechanged, the values
will be held until the unit is again powered down.
Toaccessthe Counter Load valueforthedesired counter;
first, press the “+/-” key, if necessary, so that the display is
indicating the counter value which is to be changed.
Secondly, press the “E” key and while holding it down,
press the “+/-” key.
TheGeminiwill nowdisplaythedisplayed Counter Load
value. (It will be zero, unless the value had been changed
since the unit was powered up.)
To change the value, press the key under the digit to be
changed as explained previously for the Preset.
To load the value into the counter, press the “E” key.
The display will flash momentarily and will display the
counter with the new value.
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INITIAL FACTORY CONFIGURATION DUAL COUNTER FACTORY SETTINGS*
Keys struck Display Description
4,1 41 2 Personality selected as DUAL COUNTER
4,2 42 3 Reset Counters A & B
4,3 43 1 Count with Inhibit
4,4 44 1 Single edge counting (A & B)
4,5 45 1 Counter B Scale multiplier of 1.0
4,6 46 1 Counter B leading zero blanking and no decimal point
5,1 51 2 Outputs 1 & 2 assigned to Counter B
5,2 52 3 Output 1 terminates at Reset, Normal Phase.
5,3 0000.10 Timed Output 1 Value of 0.1 Sec
5,4 54 3 Output 2 terminates at Reset, Normal Phase.
5,5 0000.10 Timed Output 2 Value of 0.1 Sec
5,6 56 1 Counter B, manual reset to zero
6,1 61 1 Counter A, manual reset to zero
6,4 64 1 Counter A scale multiplier of 1
6,5 65 1 Counter A leading zero blanking, no decimal point
6,6 66 1 No functions except Reset enabled
3 01.0000 Scale Factor A set to 1.0000
3 01.0000 Scale Factor B set to 1.0000
1 000500 Preset 1 set to 500
2 001000 Preset 2 set to 1000
* If [41 1] is changed to [41 2], then the factory settings are as shown.
Keys struck Display Description
4,1 41 1 Personality selected as COUNTER/RATE
4,2 42 3 Reset Rate (A) Output(s) & Counter (B)
4,3 43 1 Count with Inhibit
4,4 44 1 Single edge counting (B)
4,5 45 1 Counter B Scale multiplier of 1.0
4,6 46 1 Counter B leading zero blanking and no decimal point
5,1 51 2 Outputs 1 & 2 assigned to Counter (B)
5,2 52 3 Output 1 terminates at Reset, Normal Phase
5,3 0000.10 Timed Output 1 Value of 0.1 Sec
5,4 54 3 Output 2 terminates at Reset, Normal Phase
5,5 0000.10 Timed Output 2 Value of 0.1 Sec
5,6 56 1 Counter (B), manual reset to zero
6,1 61 4 No Rate (A) right hand dummy zeros
6,2 62 1 Rate per Second
6,3 63 1 Rate (A) 0.5 Sec Minimum Update Time
6,4 64 4 Rate (A) Scale multiplier of 1
6,5 65 1 Rate (A) leading zero blanking, no decimal point
6,6 66 1 No functions except Reset enabled
3 01.0000 Scale Factor A (Rate) set to 1.0000
3 01.0000 Scale Factor B (Counter) set to 1.0000
1 000500 Preset 1 set to 500
2 001000 Preset 2 set to 1000
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OPERATOR ACCESSIBLE FUNCTIONS WITH
PROGRAMMING DISABLED
(For details on keyboard entry, see preceding section)
One of the important features of the Gemini is the ability to disable
programming. With this ability, accidental bumping of the keys or tampering by
unauthorizedpersonnelcan be prevented.However,it maybe necessarytoallow
resetandcertainprogrammingfunctions,suchasPresetandScaleFactorValues,
to be changed in daily operation. The Gemini, through the use of the “Operator
Accessible Functions” Modes can enable these functions even when the “PGM.
DIS.” (Program Disable) terminal is connected to “COMMON”.
The “Operator Accessible Functions” modes are programmed by entering a
two-digit function code (66) and the desired mode. Unlikeother function codes,
the mode does not take effect immediately. The “PGM. DIS.” terminal must be
connected to “COMMON” in order for the Gemini to disable programming and
operate as per the mode programmed.
There are six basic “Operator Accessible Functions” Modes available. These
modes enable the following functions.
1. NO FUNCTIONS EXCEPT RESET ENABLED - In this mode, manual
reset is enabled, but none of the programming functions can be changed.
However, the functions can be interrogated.
2. PRESET PROGRAMMING AND RESET ENABLED - Theentirefront
panel is disabled with the exceptions of Preset programmability and manual
reset. All functions can be interrogated.
3. SCALE FACTOR PROGRAMMING AND RESET ENABLED - The
entire front panel is disabled with the exceptions of Scale Factor
programmability and manual reset. All functions can be interrogated.
4. SCALE FACTOR AND PRESET PROGRAMMING, AND RESET
ENABLED - The entire front panel is disabled with the exceptions of Scale
Factor and Preset programmability, and manual reset. All functions can be
interrogated.
5. PRESET AND COUNTER LOAD PROGRAMMING, AND RESET
ENABLED - The entire front panel is disabled with the exceptions of Preset
and Counter Load programmability. All functions can be interrogated.
6.PRESET,SCALEFACTORAND COUNTER LOAD PROGRAMMING,
AND RESET ENABLED - The entire front panel is disabled with the
exceptions of Preset, Scale Factor and Counter Load programmability. All
functions can be interrogated.
All of these modes can be modified with the addition of a “-” sign. The minus
sign disables the manual reset, at the front panel and the remote reset (RST., not
RST.A) terminal, at the rear of the unit.
Thereisalso arearpanelDIPswitchwhichpermitsdisablingofthefrontpanel
reset button. This is independent of the rear terminal remote reset, and can be
used in conjunction with any front panel disable mode. The combination of a
manual and remote reset inputs provides a high level of security without
sacrificing flexibility.
DIAGNOSTICS, SELF-TEST, & “WATCHDOG” TIMER
The security of the Gemini is further enhanced by its self-test diagnostic and
“watchdog” timer capabilities.
The diagnostics are concerned with the special, no power memory of the
Gemini. Whenever the power is turned off, all pertinent function settings and
measurements (except the Counter Load values) are automatically saved. When
power is restored, the functions and data are re-instated. This allows you to
program the unit once and not have to re-program it until you wish to use it in
another mode.
When the function codes and data are saved, computations are made with
thesevalues.Theresult of these computationsisstoredinthememoryto serve as
a check against possible error. On power up the same computations are repeated
on the stored data. If the results do not agree with the stored results, a “P” will
appearontheleftsideof thedisplay.Ifthisoccurs,refertothe“Troubleshooting
Guide” for directions.
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DIAGNOSTICS, SELF-TEST, & “WATCHDOG” TIMER [Cont’d]
Another error indicator is the “watchdog” timer. In order to insure the
software is functioning properly, the program constantlymonitors itself. If the
proper sequence and timing of internal events does not occur, an “E”will appear
onthe leftside ofthedisplay.If thisoccurs,referto the“TroubleshootingGuide”
for directions.
The final type of built-in error checking is the front panel initiated self-test. It
can be performed at any time, even when the Gemini is running. It will not
interferewiththeaccumulationofcountsorcontrolfunctions.Afunctioncodeof
“6”, “+/-” starts the test. At this time, whatever was displayed will disappear and
be replaced by a string of decimal points and the overflow indicator. Then the
displaywillshowa string of9’s,then8’setc.,untilastringof 0’s are shown. The
self-test will then turn off the overflow indicator and activate the minus “-” sign.
Then the unit shows an interlace pattern of -010101, then -212121, followed by
232323 etc., until -898989 is reached. At this time the outputs can be tested by
pressingthe“1”or“2” key. (Theprogramdisable terminalmustbedisconnected
in order to allow activation of the outputs. Also, when testing the output, use
caution, so as not to cause any undesirable or hazardous conditions in the
system.)An automatic exit will take place aftersix seconds or immediately if the
Program Disable terminal is connected to common. Normal length of display
time for each of the patterns is approximately 0.5 sec. Rapidly pressing “E”
during self-test can speed up the sequence.
INPUT CIRCUITRY & SET-UP
There are two independent input channels on the Gemini. Various types of
sensor outputs can be accommodated by appropriate DIP switch set-up. These
include: TTL or CMOS logic, current sinking, current sourcing, or dry contact
and more.
Channel 1 consists of a logic input and a separate low level magnetic pickup
input.
Channel 2 is a completely independent count or control input channel. Like
Channel 1, it can be programmed with DIP switches for a wide variety of logic
inputs, and is identical to Channel 1 in this regard. For a complete detailed
description of input set-up, see Appendix “A”.
OVERFLOW INDICATION
The Gemini features an overflow indicator (LED) which is located to the left
of the sixth digit and above the polarity annunciator.This LED will turn on if the
capacity of the display (6-digits) is exceeded or if the internal count capacity
(9-digits) is exceeded. Use of extremely small scale multiplier and Scale Factor
Values can cause the internal count capacity to overflow before the displayed
valuewould overflow. Itshould also benotedthatthe use ofRightHand Dummy
Zeros or Scale Factors larger than one could cause the displayed value to
overflow before a value of 999,999 (6-digits) is accumulated.
When the capacity of the display is exceeded, the count value will be
maintainedandwillbevalid.But iftheinternal countvalue isexceeded,then this
value may no longer be valid.
The overflow LED can also turn on under certain conditions when the rate
input frequency exceeds the maximum3250 cps allowed for a rate update period
of 16 sec. See Code 63 - “Rate Minimum Update Time”.
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