red lion Gemini 5200 Instruction Manual
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red lion Gemini 5200 Instruction Manual

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THE ASTRO LINE SERIES
GEMINI 5200 INSTRUCTION MANUAL
Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com

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  • Page 1 THE ASTRO LINE SERIES GEMINI 5200 INSTRUCTION MANUAL Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...
  • Page 2 INTRODUCTION The Gemini 5200 is another unit in a multi-purpose series of industrial control products 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

    40-41 VIII. APPENDIX “D” - DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY 42-45 IX. APPENDIX “E” - GEMINI 5200 DUAL RATE W/DISP C FUNCTION COMMAND CODE SUMMARY 46-49 APPENDIX “F” - SCALING FOR RATE & DISPLAY C 50-52 XI.

  • Page 4: General Description

    GENERAL DESCRIPTION equipped with safeguards. To do so, can be potentially harmful to persons or The Gemini 5200 is a multi-function dual rate indicator which can fulfill equipment in the event of a fault to the unit. almost any rate indication application. The unit can operate as two independent...

  • Page 5: D) Programming The Presets, Scale Factors, Timed Output Values

    The Presets and Scale Factor Values are commonly reprogrammed on a daily basis. As such, single keystroke access has been provided on the front panel. The Gemini 5200 has two Scale Factors, one for Rate Display A , and one for Rate Display B. Pressing the “3” key...
  • Page 6 PROGRAMMING THE PRESETS, SCALE FACTORS & TIMED OUTPUT VALUES [Cont’d] Note: A Timed Output Value of zero cannot be programmed into the Gemini 5200. If a value of 0 is entered into the display, and the “E” key is pressed, the unit will remain in data entry mode.

  • Page 7: E) Factory Settings

    FACTORY SETTINGS INITIAL FACTORY CONFIGURATION (DUAL RATE) DUAL RATE WITH SPEED RATIO FACTORY SETTINGS * Keys Struck Display Description Keys Struck Display Description 41 1 Personality selected as DUAL RATE W/O DISP C 41 2 Personality selected as DUAL RATE W/SPEED RATIO 42 3 Reset Rate A &...
  • Page 8 FACTORY SETTINGS [Cont’d] DUAL RATE WITH SPEED DIFF. FACTORY SETTINGS * DUAL RATE WITH SPEED DRAW FACTORY SETTINGS * Keys Struck Display Description Keys Struck Display Description 41 3 Personality selected as DUAL RATE W/SPEED DIFF. 41 4 Personality selected as DUAL RATE W/SPEED DRAW 42 3 Reset Rate A &...

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

    This allows you to program the unit once and Values, to be changed in daily operation. The Gemini 5200, through the use of the not have to re-program it until you wish to use it in another mode.

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

    Appendix “A”. OVERFLOW INDICATION The Gemini 5200 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 following conditions occur.

  • Page 11: Programming The Gemini 5200 In Dual Rate Without Display C Mode

    “+/-” key, and the “E” key is pushed to load the factory settings. The factory settings are listed on page 5 and 6. [41 1] DUAL RATE INDICATION - In this mode, the Gemini 5200 operates as CODE 43 - RATE B CONVERSION FACTOR two independent rate indicators.
  • Page 12 [44 6] 16 Secs. minimum/32 Secs. maximum (max. rate = 3250 cps) CODE 51 - OUTPUT ASSIGNMENT The outputs of the Gemini 5200 can be assigned to either the Rate A or Rate B CODE 45 - RATE B SCALE MULTIPLIER channel or one to each.
  • Page 13 [52 -5] that Output 1 is set for reverse phase operation. A reverse phase mode is available on the Gemini 5200. This refers to the [52 -6] complementing of the logic state of Output 1. With normal phase operation, when the display value reaches Preset 1, Output 1 will turn on.
  • Page 14 Note: A Timed Output Value of zero cannot be programmed into the Gemini 5200. CODE 54 - OUTPUT 2 TERMINATION MODES (Cont’d) If a value of 0 is entered into the display and the “E” key is pressed, the unit will [54 3] TERMINATE AT MANUAL RESET - Output 2 activates when the rate is not enter the 0, but will stay in the data entry mode.
  • Page 15 There are six basic modes of decimal point placement for the Rate A indicator [66 3] SCALE FACTOR PROGRAMMING AND RESET ENABLED - In this of the Gemini 5200. The decimal point is placed to the right of the display digit mode, manual reset and the programming of the Scale Factors are enabled.
  • Page 16 CODE 66 - “OPERATOR ACCESSIBLE FUNCTIONS” MODES (Cont’d) [66 -1] [66 -2] These Modes are the same as above with the [66 -3] exception that manual reset is disabled. [66 -4] PRESET VALUES Whenever the display value equals the Preset 1 or 2 Value, an output action will occur.

  • Page 17: Programming The A/B, (A-B)/B, & A-B Display C Modes

    PROGRAMMING THE A/B, (A-B)/B, AND A-B DISPLAY C MODES CODE 41 - UNIT PERSONALITY This section will deal with the programming and operation of the Gemini 5200 in the modes which include Display C, [41 2,3,4]. Since all three display C modes The unit personality mode is the first function code that is programmed.
  • Page 18 [43 2] Rate Per Minute (x60) [43 3] Rate Per Hour (x3600) CODE 51 - OUTPUT ASSIGNMENT The outputs of the Gemini 5200 can be assigned to the Rate A, Rate B, or the CODE 45 - RATE B SCALE MULTIPLIER Display C channel.
  • Page 19 [52 -6] A reverse phase mode is available on the Gemini 5200. This refers to the complementing of the logic state of Output 1. With normal phase operation, CODE 53 - TIMED OUTPUT 1 VALUE when the display value reaches Preset 1, Output 1 will turn on.

  • Page 20: D) Codes 61, 62, 63, 64, 65, 66, Preset Values, & Scale Factors A & B

    [54 -5] that Output 2 is set for reverse phase operation. A reverse phase mode is available on the Gemini 5200. This refers to the [54 -6] complementing of the logic state of Output 2. With normal phase operation, when the display value reaches Preset 2, Output 2 will turn on.
  • Page 21 In the Display C indicators of the Gemini 5200. The decimal point is placed to the right of the modes [41 2,3,4], the rate channels are synchronized. The slower of the two display digit that corresponds to the mode identifier.
  • Page 22 CODE 66 - “OPERATOR ACCESSIBLE FUNCTIONS” MODES SCALE FACTORS A & B The Gemini 5200 has four basic levels of “Operator Accessible Functions”. The Scale Factor, for whichever Value (Rate A or B) is currently being Each of these levels can be modified to enable or disable manual reset. When the displayed, is accessed by pressing the “3”...

  • Page 23: E) Gemini 5200 Programming Example - Speed Ratio Application

    Two LMPC’s are used to sense the gear teeth. Each of the rolls have a circumference of 2 feet. The Gemini 5200 can fulfill all the requirements of the system. The Gemini 5200 can provide an indication of the speed relationship, and can also provide a Feet per Minute indication of the speed at which each of the rolls are running.
  • Page 24 STEP 14 - The “+/-” key is pushed, if necessary, so that Rate A is being indicated STEP BY STEP PROGRAMMING PROCEDURE on the Gemini 5200. The “3” key is then pushed to call up the Rate A Scale Factor. The value is changed to 2.7778.

  • Page 25: Gemini 5200 20 Ma Current Loop Communications

    GCM232 Serial Converter Module is available to convert the 20 mA Current Loop signals to RS232 and vice-versa. The format that the Gemini 5200 will accept is: 1 start bit, 7 data bits, 1 odd There are two loops that must be established. One for sending commands to parity bit, and 1 stop bit.

  • Page 26: B) Sending Commands & Data To The Gemini 5200

    Reset command; operates on Output(s) assigned to used when constructing a command string. the channel being reset. 1. If the Gemini 5200, to which the command is to be sent, is assigned an address T (54H) Transmit Value command; operates on display values, other than zero, the first two characters of the command string must consist of Presets and Scale Factors.
  • Page 27 Print statement. The Gemini 5200 will not accept a carriage return or line (**) This is the time that it takes the Gemini 5200 to process the preset. It feed as valid characters. See “Terminal Emulation Program” section for a listing varies with the Count Rate and Scale Factor Value.

  • Page 28: C) Receiving Data From The Gemini 5200

    The various Print Options are used mainly in conjunction with a printer and the is shown below. Print Request Terminal. They provide a choice of Gemini 5200 data values to be printed when either the Print Request Terminal is activated or the “Transmit per Print Options”...

  • Page 29: 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 5200 (TBD), located on the right side of the top board. Refer to the numbers listed with...

  • Page 30: F) Communications Application

    The drawing below shows the Current Loop set-up. Each Five Gemini 5200s with 20 mA Current Loop Option, are used Gemini 5200 is given an address and the Serial DIP switches to monitor the speed and draw of various rollers in a printing are set accordingly.

  • Page 31: G) Troubleshooting Gemini Serial Communications & Serial Loop-Back Self-Test

    Geminis and other peripherals must be observed. If a multimeter or ammeter is properly, the Gemini 5200 will change its Scale Factor B value to 0.1111. To available, insert it in series in each Serial loop and check for current flow with perform the loop-back test, follow the test sequence as described below.

  • Page 32: Appendix "A" - Installation & Input Configuration Switch Set-Up

    APPENDIX “A” - INSTALLATION & INPUT CONFIGURATION SWITCH SET-UP Installation Environment Before installing the Gemini 5200 into the panel, the user should first become familiar with the unit. It may also be desirable to program the unit for the The GEM5200 should be installed in a location that does not exceed the application at hand (Refer to the “Programming and Applications”...
  • Page 33 SELECT AC POWER (115/230 VAC) SHIELD TERMINATION The AC power to the unit must be selected for either 115 VAC or 230 VAC. EMC compliance installation testing had the drain wire for the shielded cable The selector switch is located through an access slot on the side of the case (See terminated as shown.
  • Page 34 ADDITIONAL EMC INSTALLATION GUIDELINES Control cables as close to the unit as possible. Loop the cable through the core several times or use multiple cores on each cable for additional protection. Although this unit is designed with a high degree of immunity to Install line filters on the power input cable to the unit to suppress power line ElectroMagnetic Interference (EMI), proper installation and wiring methods interference.
  • Page 35 INPUTS A & B AND MAGNETIC PICKUP INPUTS A & B For best results, the A.C. primary power should be relatively “clean” and within The Gemini 5200 has two input channels. Input Channel A is associated with the specified +/-10% variation limits. Drawing power from heavily loaded circuits Rate Display A and Channel B is associated with the Rate Display B.
  • Page 36 BLOCK DIAGRAM Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...
  • Page 37 CONNECTIONS & CONFIGURATION SWITCH SET-UPS FOR VARIOUS SENSOR OUTPUTS (See Note 5) Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...
  • Page 38 The +12 V sensor supply voltage on the “DC OUT” terminal is nominal with corner, on the back of the Gemini 5200. Pull the tab down while sliding the board +/-25% variation due to line and internal load variations. All RLC sensors into the two slots in the housing.
  • Page 39 SENSOR INPUT CONNECTIONS & INPUT CONFIGURATION SWITCH SET-UP The accompanying diagram shows the details of the logic and magnetic pickup circuitry. The four switches used to set up Logic Input A and Magnetic Pickup A are designated S1, S2, S3, and S4. The four switches used to set up Logic Input B and Magnetic Pickup B are designated S5, S6, S7, and S8.

  • Page 40: Appendix "B" - Specifications & Dimensions

    APPENDIX “B” - SPECIFICATIONS & DIMENSIONS 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” terminal. 2. POWER REQUIREMENTS: AC Power: Switch selectable 115/230 VAC (±10%), 50/60 Hz, 20 VA 6.
  • Page 41 11. SERIAL COMMUNICATIONS: ELECTROMAGNETIC COMPATIBILITY: Type - Bi-directional 20 mA current loop, 20 mA source provided. (Powers up Immunity to EN 50082-2 to 7 units in a loop with internal current source.) Electrostatic discharge EN 61000-4-2 Level 2; 4 Kv contact Baud Rate - Programmable 300 to 2400.

  • Page 42: Appendix "C" - Troubleshooting Guide

    APPENDIX “C” - TROUBLESHOOTING GUIDE The majority of difficulties arising with the Gemini 5200 are related to incorrect hook-up and programming set-up. Always check all connections, function codes, Scale Factor, and presets 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 43 APPENDIX “C” - TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE REMEDIES INCORRECT RATE READING 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 44: Appendix "D" - Dual Rate W/O Disp C Function Command Code Summary

    APPENDIX “D” - GEMINI 5200 DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS UNIT PERSONALITY (-)Loads factory set code values* +/-1 Dual Rate W/O Display C Rate AÞDisplay A, Rate BÞDisplay B +/-2 Dual Rate W/ Ratio (A/B) See Appendix “E”...
  • Page 45 APPENDIX “D” - GEMINI 5200 DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS RATE B DECIMAL POINT & LEAD ZERO BLANKING (Cont’d) +/-1 No Decimal Point +/-2 Decimal Point Right of Digit 2 +/-3 Decimal Point Right of Digit 3...
  • Page 46 APPENDIX “D” - GEMINI 5200 DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS RATE B RIGHT-HAND DUMMY ZEROS 1 Dummy Zero 2 Dummy Zeros 3 Dummy Zeros No Dummy Zeros RATE A RIGHT-HAND DUMMY ZEROS...
  • Page 47 APPENDIX “D” - GEMINI 5200 DUAL RATE W/O DISP C FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS RATE A DECIMAL POINT & LEAD ZERO BLANKING (+) Leading Zero Blanking Enabled (-) Leading Zero Blanking Disabled* +/-1 No Decimal Point...

  • Page 48: Appendix "E" - Gemini 5200 Dual Rate W/Disp C Function Command Code Summary

    APPENDIX “E” - GEMINI 5200 DUAL RATE W/ DISP C FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS UNIT PERSONALITY (-)Loads factory set code values* +/-1 Dual Rate W/O Display C See Appendix "D" for function command code summary. +/-2 Dual Rate W/ Ratio (A/B) Rate A &...
  • Page 49 APPENDIX “E” - GEMINI 5200 DUAL RATE W/ DISP C FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS DISPLAY C DECIMAL POINT & LEAD ZERO BLNKNG (Cont’d) +/-2 Decimal Point Right of Digit 2 +/-3 Decimal Point Right of Digit 3...
  • Page 50 APPENDIX “E” - GEMINI 5200 DUAL RATE W/ DISP C FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS TIMED OUTPUT 2 VALUE Range 0.01 to 599.99 sec. DISPLAY C MULTIPLIER Not available in mode [41 3], Speed Difference x100 x1000...
  • Page 51 APPENDIX “E” - GEMINI 5200 DUAL RATE W/ DISP C FUNCTION COMMAND CODE SUMMARY CODE MODE DESCRIPTION COMMENTS RATE A & B DECIMAL POINT & LEAD ZERO BLNKNG (+) Leading Zero Blanking Enabled (-) Leading Zero Blanking Disabled* +/-1 No Decimal Point...

  • Page 52: Appendix "F" - Scaling For Rate & Display C

    APPENDIX “F” - SCALING FOR RATE & DISPLAY C The Gemini 5200 offers a simplified method of scaling the rate indicator. The Using the example previously discussed, the display unit would be 1 method does not require time unit conversions. The desired time format (Rate Per revolution and the number of pulses per display unit would be 48.
  • Page 53 NUMBER OF PULSES = 400 Rev x 14 Pulses per Rev = 5600 pulses. Gemini 5200 was set-up in mode [41 2], Dual Rate with Speed Ratio, and the rate indicators were programmed to indicate rate with no decimal point. With actual rates of 1.5 PPS for Rate A, and 1 PPS for Rate B the rate displays would both...
  • Page 54 RATE SCALING EXAMPLES (Cont’d) We now have all the information necessary to scale the rate. The Total Scaling Factor “K ”, is calculated using Formula #1 as shown below. = Display Units/Number of Pulses = 810/5600 = 0.144643 It is noticed that there are more significant digits in the Total Scale Factor, ”, than there are available for Scale Factor, “SF”.

  • Page 55: Appendix "G" - Gemini 5200 Programming Charts

    Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...
  • Page 56 Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...

  • Page 57: C) Codes 51, 52, 53, 54

    Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...

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

    Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...

  • Page 59: Appendix "H" - Ordering Information

    ¾ Gemini 5200 Relay Board RLYBD002 For Information on Pricing, NEMA Enclosures, Base Mount Kits, & Panel Adapter Kits, refer to the Red Lion Controls Catalog or contact your local RLC distributor. Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...
  • Page 60 This page is intentionally left blank. Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...
  • Page 61 This page is intentionally left blank. Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...
  • Page 62 This page is intentionally left blank. Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com...
  • Page 63 Company’s option. The Company disclaims all liability for any affirmation, promise or representation with respect to the products. The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against damages, claims, and expenses arising out of...

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