Gemini 4100 Instruction Manual
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Gemini 4100 Instruction Manual

Gemini 4100 Instruction Manual

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THE ASTRO LINE SERIES
GEMINI 4000 INSTRUCTION MANUAL
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com

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  • Page 1 THE ASTRO LINE SERIES GEMINI 4000 INSTRUCTION MANUAL Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    15-17 C) Dual Preset Counter & Rate Application 18-19 III. PROGRAMMING INSTRUCTIONS FOR THE DUAL COUNTER VERSION OF THE GEMINI 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 Factors A &...

  • Page 4: General Description

    The Gemini 4000 series consists of two basic units, a single preset version, the programming the “Rate Minimum Update Time” (0.5 sec. to 16 sec.) for the Gemini 4100, and a two preset version, the Gemini 4200. Each basic unit is also desired response. Extensive scaling capabilities allow practically any desired available in 115/230 VAC versions, with or without Serial communications and a reading at very slow count rates.

  • Page 5: B) Programming The Gemini

    “+” or minus When your Gemini arrives from the factory, it has already been programmed “-” sign. In the cases where a “+” sign is required, no sign will to function as a counter and rate indicator.
  • Page 6 Thus, if an odd Preset Value The display will immediately return to the count value. is entered, such as 6.7 ft., the Gemini will alter the Preset display to read in even tenths of feet.
  • Page 7 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 code 66. The “Counter Load Value” is not stored when the unit is powered down.

  • Page 8: E) Initial Factory Configuration Counter/Rate & Dual Counter Factory Settings

    INITIAL FACTORY CONFIGURATION DUAL COUNTER FACTORY SETTINGS* Keys struck Display Description Keys struck Display Description Personality selected as COUNTER/RATE Personality selected as DUAL COUNTER Reset Rate (A) Output(s) & Counter (B) Reset Counters A & B Count with Inhibit Count with Inhibit Single edge counting (B) Single edge counting (A &...

  • Page 9: F) Operator Accessible Functions With Programming Disabled

    Preset and Scale Factor Values, RST.A) terminal, at the rear of the unit. to be changed in daily operation. The Gemini, through the use of the “Operator There is also a rear panel DIP switch which permits disabling of the front panel Accessible Functions”...

  • Page 10: H) Input Circuitry & Set-Up

    It should also be noted that the use of Right Hand Dummy can be performed at any time, even when the Gemini is running. It will not Zeros or Scale Factors larger than one could cause the displayed value to interfere with the accumulation of counts or control functions.

  • Page 11: Programming Instructions For The Counter/Rate Version Of The Gemini

    The Gemini can be programmed to operate in one of two different [42 2] RESET COUNTER (B) personalities. In each of the two unit personalities, the Gemini operates as a dual [42 3] RESET RATE (A) OUTPUT(S) AND COUNTER (B) function indicator.
  • Page 12 CODE 44 - COUNTER (B) NUMBER OF COUNT EDGES as the subtract input (count decrements). The counter of the Gemini can be programmed for either single or two edge (x2) counting. The number of count edges cannot be set when the count mode is [43 4] SEPARATE INPUT - In this mode, the two functions, Counter (B) and Rate (A) are independently controlled by the inputs.
  • Page 13 There are four Counter B Scale Multipliers that are available. They effectively The output(s) of the Gemini 4000 can be assigned to either the rate or count divide the internal Count B value by 1, 10, 100, and 1000 respectively, to yield channel.
  • Page 14 Preset 1 Value. Output 1 will Note: A Timed Output Value of zero cannot be programmed into the Gemini. If a activate every update time period for which the above conditions are true. If value of 0 is entered into the display and the “E”...
  • Page 15 A reverse phase mode is available on the Gemini 4200. This refers to the negative than (only possible with counter) or equal to Preset 2, Output 2 is complementing of the logic state of the output. With normal phase operation, activated.
  • Page 16 Preset at the beginning of Timed Output (at zero). The Timed Output Value Note: For the Gemini 4200, all reset to preset modes reset to preset 2 and Timed must be shorter than the time required for the counter to count to zero, Output refers to Output 2.

  • Page 17: B) Codes 61, 62, 63, 64, 65, 66, Preset Values, Scale Factors A & B, Counter Load Value

    There are six basic modes of decimal point placement for the Rate indicator of time unit that the rate is to displayed in. See Appendix “F” - Scaling For Rate. the Gemini. The decimal point is placed to the right of the display digit that [62 1] Rate Per Second (x1) corresponds to the mode identifier.
  • Page 18 Scale Factor. If it is not, [66 2] PRESET PROGRAMMING AND RESET ENABLED - In this mode, the Gemini will automatically adjust the preset value up or down to force it to be manual reset and the programming of the Preset Values are enabled.
  • Page 19 10ths. In this case, the display will increment by two for each count input. Thus if an odd Preset Value was entered, such as 6.7 ft., the Gemini will alter the preset to read in even tenths of feet.

  • Page 20: C) Dual Preset Counter & Rate Application

    The operator will then make the cut, load a new take up roll and reset the Gemini to start a new roll. In addition to cut to length, the same Gemini 4200 is to be used to indicate the speed of the wire screen in feet per minute, while providing a “overspeed”...
  • Page 21 STEP 2 - Enter code 42 (Reset Button & Terminal Actuation Modes). Select and on the Gemini 4200. The “3” key is then pushed to call up the Rate Scale enter mode 2 to reset the counter when reset is activated.

  • Page 22: Programming Instructions For The Dual Counter Version Of The Gemini

    CODE 41 - UNIT PERSONALITY CODE 43 - INPUTS 1 & 2 RESPONSE MODES The Gemini can be programmed to operate in one of two different unit The Gemini has six different input response modes. They are: Count(1) with personalities. In each of the two personalities the Gemini operates as a dual Inhibit(2);...
  • Page 23 CODE 44 - COUNTERS A & B NUMBER OF COUNT EDGES independently controlled by the inputs. Input 1 serves as the Counter A input The counters of the Gemini can be programmed for either single or two edge and Input 2 serves as the Counter B input.
  • Page 24 [52 2] TERMINATE AT OUTPUT 2 END - Output 1 will terminate when The output of the Gemini 4100 is assigned to Counter B, or for the Gemini Output 2 ends. Output 1 is set for normal phase operation. (Gemini 4200 Only) 4200 one can be assigned to Counter B and the other to Counter A.
  • Page 25 (code 55) Note: A Timed Output Value of zero cannot be programmed into the Gemini. If a has expired. Manual reset will override the timed output and reset Output 2.
  • Page 26 CODE 55 - TIMED OUTPUT 2 VALUE (GEMINI 4200 ONLY) panel reset is enabled, by pressing the front panel reset button. Reset is The Gemini 4200 has the capability of varying the Timed Output 2 Value from “maintained”. 0.01 second to 599.99 seconds. When the code is entered, instead of a single mode identifier digit being displayed, six digits will be shown.

  • Page 27: C) Codes 61, 64, 65, 66, Preset Values, Scale Factors A & B, Counter Load Values

    OUTPUT 1 (AT ZERO) - In this reset mode, the counter will automatically For the Gemini 4200, if both outputs are assigned to Counter B [51 2], or the reset to Preset 1 at the beginning of Timed Output 1 (at zero). The Timed 1...
  • Page 28 Preset Values are enabled. There are six basic modes of decimal point placement for Counter A of the Gemini. The decimal point is placed to the right of the display digit that [66 3] SCALE FACTOR PROGRAMMING AND RESET ENABLED - In this corresponds to the mode identifier.
  • Page 29 Thus if an odd preset value was entered, such as 6.7 ft., the Gemini will alter the preset to read in even tenths of feet. Note: Use of a small Scale Factor in conjunction with a small scale multiplier could cause the internal count value to be exceeded before the 6-digit display value is exceeded.

  • Page 30: E) Dual Counter Batching Application

    The “HI/LO FRQ” switch is placed in the “HI FRQ” position since the scaling. The Gemini 4200 is simply left at its factory settings of 1 for Scale Factor count frequencies involved will be over 100 cps. The “EN/DIS RST” switch (8), A and Scale Multiplier A.
  • Page 31 1 pulse will provide for 1 “Display Unit” of indication (1 enter mode 2 for Preset programming and reset enabled. When the hundredth of an inch). The Gemini 4200 can therefore be left at its Scale Factor B “PGM.DIS.” terminal is connected to “COMM.”, the only changes that will be and Scale Multiplier B factory settings of 1.

  • Page 32: 20 Ma Current Loop Communications

    Change Display command; operates on Display values E & F. formats and Baud Rates. The format that the Gemini will accept is: 1 start bit, 7 data bits, 1 odd parity bit, and 1 stop bit. The Baud Rates that are available are:...
  • Page 33 During this time, only one additional command may be sent to the Gemini. 1. If the Gemini, to which the command is to be sent, is assigned an address other This may be done 80 msec after the transmission of the “Change Value”...

  • Page 34: C) Receiving Data From The Gemini

    The first two digits transmitted are the unit address followed by two blank (**) This is the time that it takes the Gemini 4000 to process the preset. spaces. If the unit address is 0, the first locations will be left blank. The next three It varies with the Count Rate and Scale Factor Value.

  • Page 35: D) Print Options

    The various Print Options are used mainly in conjunction with a printer and the Print Request Terminal. They provide a choice of Gemini data values to be printed when either the Print Request Terminal is activated or the “Transmit per Print Options”...

  • Page 36: E) Current Loop Installation

    When wiring the 20 mA current loop, remove the 7-position terminal block PR.ID - PRINT ID. - When this switch is in the up position, the Gemini will print (TBD), located on the right side of the top board. Refer to the numbers listed with...

  • Page 37: F) Communications Application

    The drawing below shows the Current Loop set-up. Each monitor and control parts packaging machines in a plant. The Gemini is given an address and the Serial DIP switches are set units are located at each of the machines in the production area accordingly.

  • Page 38: G) Troubleshooting Gemini Serial Communications & Serial Loop-Back Self-Test

    If too much current has been sent shown in the diagram below. 2. Set the Gemini’s unit address to 15 (set switches 7-10 of the Serial DIP Switch through a Serial Input or Output, the unit may have been damaged. If a Gemini to the down position).

  • Page 39: Appendix "A" - Installation & Input Configuration Switch Set-Up

    PANEL MOUNTING {Note: See Appendix “B” for dimensions} The Gemini is intended to be mounted into an enclosed panel with a gasket to provide a water-tight seal. The unit meets NEMA 4/IP65 requirements for indoor use when properly installed. Two mounting clips and screws are provided for easy installation.
  • Page 40 SELECT AC POWER (115/230 VAC) Shield Termination EMC compliance installation testing had the drain wire for the shielded cable The AC power to the unit must be selected for either 115 VAC or 230 VAC. terminated as shown. The drain wire was less than 0.5" (12.7 mm) long. The selector switch is located through an access slot on the side of the case (See the Installation Figure on the previous page, or the label on the case).
  • Page 41 Additional EMC Installation Guidelines Install line filters on the power input cable to the unit to suppress power line interference. Install them near the power entry point of the enclosure. The Although this unit is designed with a high degree of immunity to following EMI suppression devices (or equivalent) are recommended: ElectroMagnetic Interference (EMI), proper installation and wiring methods Ferrite Suppression Cores for signal and control cables:...
  • Page 42 (contacts, relays, motors, etc.) should be avoided. The Gemini can be purchased with a 20 mA Current Loop Communications The voltage selector switch, located on the side of the unit, is used to select the Option.
  • Page 43 The +12 V sensor supply voltage on the “DC OUT” terminal is nominal with corner, on the back of the Gemini. Pull the tab down while sliding the board into +/-25% variation due to line and internal load variations. All RLC sensors the two slots in the housing.
  • Page 44 CONNECTIONS & CONFIGURATION SWITCH SET-UPS FOR VARIOUS SENSOR OUTPUTS (See Note 5) Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 45 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 46 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 47 SENSOR INPUT CONNECTIONS & INPUT CONFIGURATION SWITCH SET-UP The accompanying diagram shows the details of Input 1, Input 2, and Magnetic Pickup circuit. The schematic circuit for Input 2 is almost identical to that of Input 1, with the exception that Input 2 does not have the Magnetic Pickup circuitry paralleled with it.

  • Page 48: Appendix "B" - Specifications & Dimensions

    APPENDIX “B” - SPECIFICATIONS & DIMENSIONS Hi Bias - Input trigger levels V = 5.5 V, V = 7.5 V Note: Bias levels given are ±10% @ 12 VDC. They vary proportionally with 1. DISPLAY: 6-digit 0.56" (14.2 mm) High LED display. sensor supply voltage at “DC OUT”...
  • Page 49 ELECTROMAGNETIC COMPATIBILITY: DUAL COUNTER MODE [41 2] Immunity to EN 50082-2 MODE EN 61000-4-2 Level 2; 4 Kv contact Electrostatic discharge Uni or Bi-directional 9 KHz 4.5 KHz Anti-Coincidence Add/Subtract 5 KHz 2.5 KHz Level 3; 8 Kv air Separate Input 7.5 KHz 3.5 KHz Electromagnetic RF fields...

  • Page 50: Appendix "C" - Troubleshooting Guide

    APPENDIX “C” - TROUBLESHOOTING GUIDE The majority of difficulties arising with the Gemini are related to incorrect hook-up and programming set-up. Always check all connections, function codes, Scale Factors, and preset as a first step in troubleshooting. Before applying power, double check all wiring. Improper AC voltage or AC connections may result in permanent damage to the unit.
  • Page 51 APPENDIX “C” - TROUBLESHOOTING GUIDE (Cont’d) PROBLEM POSSIBLE CAUSE REMEDIES UNIT COUNTS INCORRECTLY 1. Input type incorrectly selected. 1. Check rear panel DIP switches. Turn on LO FRQ. switch for count speed of less than 100 cps. 2. Inputs incorrectly connected or loose connections. 2.
  • Page 52 APPENDIX “D” - GEMINI COUNTER/RATE MODE FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS UNIT PERSONALITY (-)Loads factory set code values* Rate Display → value (A)/Counter → Display value (B) +/-1 Counter/Rate* RESET BUTTON & TERMINAL ACTUATION MODES Reset Rate Output...
  • Page 53 APPENDIX “D” - GEMINI COUNTER/RATE MODE FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS OUTPUT ASSIGNMENT (+) Preset Tracking Disabled (-) Preset Tracking Enabled Preset 1 tracks Preset 2 +/-1 Output 1 to Rate A, Output 2 to Counter B +/-2 Outputs 1 &...
  • Page 54 * Polarity sign is displayed in front of the identifier, a (-) sign is displayed, a (+) sign is not. ** For the Gemini 4200, all reset to preset modes reset to preset 2 and Timed Output refers to Output 2.
  • Page 55 APPENDIX “D” - GEMINI COUNTER/RATE MODE FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS RATE SCALE MULTIPLIER (Cont’d) 0.01 RATE DECIMAL POINT & LEAD ZERO BLANKING (+) Leading Zero Blanking Enabled (-) Leading Zero Blanking Disabled* +/-1 No Decimal Point...
  • Page 56 APPENDIX “D” - GEMINI DUAL COUNTER MODE FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS UNIT PERSONALITY (-)Loads factory set code values* +/-2 Dual Counter* Counter A→Display value (A)/Counter B→Display value (B) RESET BUTTON & TERMINAL ACTUATION MODES Reset Counter A Reset affects the outputs as well as the displayed value.
  • Page 57 APPENDIX “D” - GEMINI DUAL COUNTER MODE FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS OUTPUT ASSIGNMENT (+) Preset Tracking Disabled (-) Preset Tracking Enabled* Preset 1 tracks Preset 2 +/-1 Output 1 to Counter A, Output 2 to Counter B +/-2 Outputs 1 &...

  • Page 58: B) Codes 51, 52, 53, 54, 55

    * Polarity sign is displayed in front of the identifier, a (-) sign is displayed, a (+) sign is not. ** For the Gemini 4200, all reset to preset modes reset to preset 2 and Timed Output refers to Output 2.
  • Page 59 APPENDIX “D” - GEMINI DUAL COUNTER MODE FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS CNTR A DECIMAL POINT & LEAD ZERO BLANKING (+) Leading Zero Blanking Enabled (-) Leading Zero Blanking Disabled* +/-1 No Decimal Point +/-2 Decimal Point Right of Digit 2...

  • Page 60: Appendix "E" - Scaling For Counting

    APPENDIX “E” - SCALING FOR COUNTING WHERE: The Gemini is factory set to provide 1 count on the display for each pulse that is input to the unit. In many applications, there will not be a one to one DISPLAY UNITS - The number of units (revolutions, feet, 10ths of feet, meters, correspondence between input pulses and display units.
  • Page 61 Once the Number of Count Edges (NCE) to be used has been determined, the STEP 2 - In this application 62 pulses per gallon provides more than enough Remaining Scaling factor required, “K ”, can be calculated. This is simply the resolution, so the “Number of Count Edges”...

  • Page 62: Appendix "F" - Scaling For Rate

    In order to convert the pulse units to revolutions, it is necessary for the Gemini APPENDIX “F” - SCALING FOR RATE to multiply the number of pulses by a scaling factor to convert the pulse units to The Gemini offers a simplified method for scaling the rate indicator. The revolution units.
  • Page 63 After the Scale Factor and Scale Multiplier values are selected, all that is With the Gemini, it is not necessary to deal with time unit conversions. From necessary to complete the scaling is to choose the Rate Conversion Factor. The...

  • Page 64: Appendix "G" - Gemini 4100 Programming Charts

    Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 65 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 66 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 67: Appendix "H" - Gemini 4200 Programming Charts

    Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 68 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 69 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 70 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 71 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 72: Appendix "I" - Ordering Information

    Gemini 4100 GEM41160 GEM42060 GEM42 Gemini 4200 GEM42160 Gemini 4100 Relay Board RLYBD001 Gemini 4200 Relay Board RLYBD002 For Information on Pricing, Enclosures & Panel Mount Kits, refer to the RLC Catalog or contact your local RLC distributor. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 73 LIMITED WARRANTY The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to two years from the date of shipment, provided the products have been stored, handled, installed, and used under proper conditions. The Company’s liability under this limited warranty shall extend only to the repair or replacement of a defective product, at The Company’s option.

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4200

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