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9. Maintenance and Fault Finding

GEM80-400

Page 9-14

ALSPA GEM

 

80-400 SERIES CONTROLLERS TECHNICAL MANUAL

Issue 3  04/99

It should be noted that if the only reference to a B-table, or the only reference to
a Fast I/O Module, is deleted from a program and a recompilation performed, the
I/O hardware associated with that table will no longer be scanned.  This could
result in outputs being left in an uncontrolled state until the next power up.

9.7.5.  Compilation Errors and the Controller

Compilation errors cause the controller to continue executing the previous
successfully compiled version of the user program, and give a fault report from
the failed compilation.  The System Log, available only with Gemesys 3, can
display up to 50 compiler error messages (out of 100 System Log locations).

When the controller is running and the user makes changes to the source version
of the program, the status is displayed on the programming tool as CHANGED
instead of RUNNING until such time as the user recompiles.  If the controller is
running with status CHANGED and there is a power interruption, the controller will
go into halt mode after power-up and give a fault report: "PROGRAM DIFFERENT
FROM RUNNING VERSION", or "POWER REMOVED WHILE PROGRAM IN A CHANGED
STATE".

As part of the self-test procedures which the controller undertakes, there is a
check that there has not been any alteration to program instructions and data in
the P-table.  Each time the user makes changes to his program or P-table data,
the controller has to recalculate a CRC value.  If power is interrupted before this
calculation is complete, the warning message: "CRC NOT STORED, PROGRAM
MAY HAVE CHANGED" is displayed on power up, and the controller goes into halt
mode.  The user may, however, run the program if desired.

9.8. 

System Status at Power Up (#500 to #699)

If, during the power-up self-test cycle, one of these fault conditions is detected,
the GEM

 

80-400 Controller will remain in the 'halt' condition and return the fault

message until the fault is cleared.  The fault messages are detailed in Table 9.3.

Table 9.3 - System Status Error Messages

Code

Fault Message

Possible Causes

Recommended

Recovery

#501

Monitor
Firmware CRC
Test Fail.

Firmware has been
corrupted.

Power off/on.  If this does
not work the board is
permanently damaged.

#502

System
Firmware CRC
Test Fail.

Firmware has been
corrupted.
A failure occurred during
firmware update.

Power off/on.
Update firmware.  If this
does not work the board
is permanently
damaged.

#503

No Valid System
Code Found.

Power off/on  If this does
not work the board is
permanently damaged.

Summary of Contents for GEM80-400 Series

Page 1: ...GEM80 400 Series Controllers Technical Manual ABCD...

Page 2: ......

Page 3: ...ALSPA GEM80 400 Series Controllers Technical Manual Publication No T1614 Issue 3...

Page 4: ...TECHNICAL MANUAL Page i ALSPA GEM80 400 SERIES CONTROLLERS Technical Manual Publication No T1614 ALSTOM DRIVES CONTROLS Kidsgrove Stoke on Trent Staffordshire ST7 1TW ENGLAND Telephone 44 0 1782 78100...

Page 5: ...ue 3 04 99 ISSUE INFORMATION The issue of various chapters of the GEM80 400 manual are individually controlled The current issue status of the manual is 20 01 98 Issue 2 Major revisions to all section...

Page 6: ...accordance with Protection of Electrostatic Sensitive Devices Part 1 General Requirements EN 100015 Pt 1 1992 CECC 00015 1992 must be observed All products weighing in excess of 20 kg 44 lbs should be...

Page 7: ...he earth terminal must be connected to earth safety ground in accordance with local safety regulations and IEC 364 5 54 The products must be protected against excessive mechanical stresses In particul...

Page 8: ...is reapplied there is danger of serious personal injury and damage to property Your attention is also drawn to the electromagnetic emission and susceptibility screening provided by the enclosure Thes...

Page 9: ...L This equipment or any part of the equipment should be disposed of in accordance with the relevant legislation in the United Kingdom disposal should therefore be carried out in accordance with the De...

Page 10: ...a non carcinogenic electrolyte which has a low acute toxicity which may cause slight irritation to the skin if contact is prolonged 6 HAZARDOUS COMPONENTS Components that may include hazardous substan...

Page 11: ...COSHH GEM80 400 Page viii ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 This page left intentional blank...

Page 12: ...xxiv 4 2 User Program Storage in EPROM xxiv 4 3 I O Modules xxv 4 4 FIP xxv 5 GEM 80 400S and 400 Enhanced System Specific Features xxv 5 1 Central Highway xxv 5 2 IMAGEM CRT Monitor Frequency Select...

Page 13: ...r Module 1 9 1 7 9032 Power Supply 1 11 1 8 9017 9018 Power Supply Module 1 12 1 9 I O Modules 1 12 1 10 Central Highway Modules 1 13 1 10 1 8272 Memory Module RAM 1 13 1 11 GEM80 400 Controller Backp...

Page 14: ...2 9 2 6 1 Free running Cycle Time 2 9 2 6 2 Preset Cycle Time 2 9 2 6 3 Calculating the Program Scanning Interval 2 10 2 7 Program Operation 2 11 2 7 1 Programmer Units 2 11 2 7 2 Remote Programming...

Page 15: ...onal Instructions 2 38 2 14 1 Set Reset Coils 2 38 2 14 1 1 Function 2 38 2 14 1 2 Format 2 38 2 14 1 3 Operation 2 38 2 14 1 4 Program Entry 2 39 2 14 1 5 Programming Rules 2 39 2 14 1 6 Monitoring 2...

Page 16: ...r 8191 Verification I O Expanders 3 20 3 10 4 Powering I O Modules through the I O Highway Ribbon Cables 3 21 3 10 5 Powering I O Subracks from the Controller Power Supply Using Discrete Wiring 3 23 3...

Page 17: ...ter Port Messages 4 14 4 4 6 2 Using the Editor 4 15 4 4 6 3 Errors 4 17 4 5 Serial Communication Between Two or More GEM 80 Controllers ESP Protocol 4 17 4 5 1 Operation as an ESP Tributary Port 4 18...

Page 18: ...15 5 12 2 Adding Fast I O Equipment 5 17 5 12 2 1 Adding Fast I O to GEM80 400S Controllers 5 17 5 12 2 2 Adding Fast I O to GEM80 400 Enhanced Controllers 5 17 5 12 3 C D Table Mapping for Fast I O I...

Page 19: ...pply Connection 7 13 7 8 Installation of Modules 7 13 7 8 1 Module Retention 7 13 7 9 Address Decoder Switches and Address Marking 7 14 7 9 1 Address Decoder Switches 7 14 7 9 2 Address and Module Lab...

Page 20: ...ower Up 500 to 699 9 12 9 9 Self test and Self test Failure Error Messages 700 to 799 9 15 9 9 1 Self test Error Messages 700 to 799 9 15 9 9 2 Self test System 9 17 9 9 2 1 Execution 9 17 9 9 2 2 Fau...

Page 21: ...ppliers 10 4 11 Watchdog and Safety Circuits 11 1 11 1 Introduction 11 1 11 2 Safety Earth Connections 11 2 11 3 Watchdog Contacts 11 2 11 3 1 Typical Watchdog Circuits 11 3 11 3 2 Watchdog Contact Ra...

Page 22: ...GEM80 400 Table of Contents Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Page xix This page left intentionally blank...

Page 23: ...Table of Contents GEM80 400 Page xx ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 This page left intentionally blank...

Page 24: ...may be directly connected to plant equipment via the front panel mounted industry standard D types and do not require termination panels All the serial port connectors are provided with plant connect...

Page 25: ...ms All GEM80 400 Series Controllers allow some I O to be used in the controller subrack 2 4 1 Basic and Verification I O The GEM80 400 Controller provides 256 bits of Basic I O and up to 1024 words of...

Page 26: ...sed wherever a coil can be used Coil_1 R G0 1 Reset Coil Rung input 0 then Bit 0 Rung input 0 then Bit unchanged Can be used wherever a coil can be used LABEL 10 Label Identifies position 10 in the la...

Page 27: ...engineers Application error numbers are prefixed with a and system error numbers are prefixed with a 3 4 System Log The controller maintains a battery backed and time stamped log of the last 100 syste...

Page 28: ...erred to and from EPROM by issuing a simple command from the programming tool 4 3 I O Modules I O Subracks to contain the Basic and Verification I O Modules may be mounted either underneath the contro...

Page 29: ...3 may be fitted In this case the slot position is fixed and the 8300 4003 must be fitted to the slot on the immediate right of the GEM80 400 Processor Module 5 2 IMAGEM CRT Monitor Frequency Selection...

Page 30: ...ng the coding plug for slot 1 from the Central Highway position to the Fast I O position fitting a 8300 4003 Fast I O Driver Module in the controller subrack and connecting the controller subrack to F...

Page 31: ...r failure to automatically shut down the controller The use of undocumented V table Features Timing dependent upon the controllers free running scan time 131 user programs that use the DELAY instructi...

Page 32: ...rollers may be supported by stocking the GEM80 400 Processor Module for the Enhanced Controller which may be easily be converted to a Standard Controller Processor Module by removing its screening pan...

Page 33: ...section 7 5 Key Switch A security key switch is mounted on the front panel of the GEM 80 400 Processor Module The Key Switch governs the controller s mode of operation and has three positions labelled...

Page 34: ...a corruption The GEM80 400 controller will produce a battery low warning when the battery is within 3 weeks of the end of its useful life This battery low warning is delivered by flashing the word BAT...

Page 35: ...functionality is stored in FLASH EPROM and may be updated by the user on site using a user friendly DOS based PC compatible firmware update utility See Chapter 9 Maintenance and Fault Finding This fir...

Page 36: ...GEM80 400 Product Overview Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Page xxxiii This page left intentionally blank...

Page 37: ...This chapter gives brief details of the internal architecture and operation of the controller The GEM 80 Instructions and Special Functions Set and the use of data tables are also given 1 1 3 Chapter...

Page 38: ...ere general cleaning and inspection procedures are described in addition to lists of the Error Messages that can be generated by the GEM 80 400 Series Controllers Fault table information and serial li...

Page 39: ...manual details how such a system can be achieved Before handlingGEM 80 equipment your attention is drawn to the sections detailing Handling Precautions for Printed Circuit Boards and Safety and Handli...

Page 40: ...ation later in this chapter the GEM 80 400 Controller provides considerable memorysize and I O capacity Figures 1 1 and 1 2 and 1 2A illustrate the GEM80 400 Standard Controller the GEM80 400S Control...

Page 41: ...400 Controller together with its power supply Standard 9032 400S 9017 Enhanced 9017 or 9018 and backplane assembly is housed in a single 19 inch subrack This subrack can also accommodate up to eight B...

Page 42: ...g while ten yellow LED s provide five pairs of outgoing and incoming serial communication and FIP network connection indicators The front panel also houses a three position key switch providing halt p...

Page 43: ...nks Communication to GEM 80 400 Controllers and other peripherals such as printers keyboards and other controllers is most commonly achieved by using the GEM 80 ESP Extended Simple Protocol other prot...

Page 44: ...editor for generation of printer port messages Flexible data table sizes Battery backed integral real time clock for time and date Comprehensive monitoring supported by diagnostic messages Transfer o...

Page 45: ...400 Standard or GEM 80 400 Enhanced and the subrack reference number R0 for a controller subrack usually R1 or R2 for an I O subrack is fitted into the upper rail of the subrack The lower rail holds a...

Page 46: ...Page 1 10 ALSPA GEM80 400 CONTROLLER TECHNICAL MANUAL Issue 3 04 99 The 8239 Processor Module is shown in Figure 1 3 Details of the processor module can be found in Chapter 2 of this manual Figure 1...

Page 47: ...the Standard Controller It should be noted that the 9032 Power Supply Module is factory set to 220V This setting may need to be adjusted depending on the user s requirements The specification for the...

Page 48: ...specifications of both power supply modules are contained in Chapter 6 of this manual recommendations for determining power requirements are also given here Figure 1 5 9017 Power Supply Module Note D...

Page 49: ...s A selection of Basic and Verification I O Modules is shown in Figure 1 6 Figure 1 6 Basic and Verification I O Modules 1 10 Central Highway Modules 1 10 1 8272 Memory Module RAM This module contains...

Page 50: ...n Label 6 PROG LED 2 Module Type Number 7 EPROM Sub module optional 3 PROG PASS LED 8 Battery Pack 4 Battery Low LED lit for battery low 9 Ejection Handle 5 PROG FAIL LED Figure 1 7 8272 Memory Module...

Page 51: ...1 Introduction Issue 3 04 99 ALSPA GEM80 400 CONTROLLER TECHNICAL MANUAL Page 1 15 1 Module Function Label Figure 1 9 IMAGEM Module 2 Module Ordering Number 3 Ejection Handle Figure 1 8 Fast I O Driv...

Page 52: ...1 Introduction GEM80 400 Page 1 16 ALSPA GEM80 400 CONTROLLER TECHNICAL MANUAL Issue 3 04 99 Figure 1 10 STARNET Module Figure 1 11 GEMLAN Module...

Page 53: ...odule interlock resistors R1 R8 0VG 0V 3 Output enable circuit links R14 and R15 VPV Verification Power Valid not used 4 Earth terminal E1 R5 15V Verification Input 5 Basic I O ribbon cable connector...

Page 54: ...roduction GEM80 400 Page 1 18 ALSPA GEM80 400 CONTROLLER TECHNICAL MANUAL Issue 3 04 99 Figure 1 13 GEM 80 400 Enhanced Controller Upper Backplane type 25X9707 with exploded view centre and right hand...

Page 55: ...tors at the left hand end rather than four basic verification connectors In addition it has two Faston connectors immediately to the left of the processor connector to allow a 15V fast I O supply to b...

Page 56: ...al Block TB3 4 Enable Output 8 0VG Signal Ground 3 Enable Input 7 0VG Signal Ground 2 Interlock Output 6 0VG Signal Ground 1 Interlock Output 5 5V Output 8 Watchdog Terminal Block TB1 4 5V Input 2 Wat...

Page 57: ...ords up to 256 points of I O One Basic I O and one Verification I O port for connecting additional I O Subracks Up to 1024 16 bit words of Verification I O which can be converted to Basic I O Remote I...

Page 58: ...trial Control Equipment CSA Approval C22 2 142 Process Control Specifications Mounting 19 inch 483mm panel mounting conforms to IEC 297 1 1975 Dimensions of Panels and Racks Dimensions Height 356mm Wi...

Page 59: ...This setting may need to be adjusted depending on the user s requirements GEM80 400 Enhanced Controllers can be operated either from a single phase ac supply or a dc supply The input voltage must be w...

Page 60: ...for short pre commissioning periods during installation in a humid location it is recommended that the cubicle be fitted with anti condensation heaters and the equipment be thoroughly dried out prior...

Page 61: ...edance is 377 5 In the near field both the electric and the magnetic components of the field must be considered Calculations based on the formula above which result in distances less than two metres a...

Page 62: ...r own individual packing remove them from the cardboard box but leave them in the protective static shielding bag or with the conductive foam shorting strip on until they are plugged into the equipmen...

Page 63: ...ed in accordance with the instructions given in Chapter 6 1 15 3 High Voltages Dangerous voltages arising from the mains supply and feedback from the plant wiring may be present within the controller...

Page 64: ...to prevent accidental mobilisation of plant and machinery or other possible hazards 1 15 8 Watchdog and Safety Circuits The requirements for watchdog and safety circuits of Chapter 11 must be designed...

Page 65: ...S CONTROLS West Avenue Kidsgrove Stoke on Trent Staffordshire ST7 1TW ENGLAND They must be securely packaged and any exposed electrical connections adequately covered with insulating tape to avoid sho...

Page 66: ...he supply but only to investigate when all signs of combustion have ceased Avoid fume inhalation Cell remains should then be disposed of as described earlier in 1 to 7 of this section Many types of ex...

Page 67: ...sk Type of Hazard Lithium Foil High May ignite in air Evolves Hydrogen flammable with water which becomes corrosive Electrolyte Dioxolane Lithium Perchlorate High Highly flammable On evaporation leave...

Page 68: ...memory modules and executes the compiled user program The Fast I O Driver which may be fitted in the Enhanced Controller only provides a buffer for data exchanges between the Central Highway and any F...

Page 69: ...outputs data based upon the user program and plant information The third phase is dependent upon the continual self checks carried out by the controller or on the detection of a system fault In the e...

Page 70: ...s in order to make the cycle time up to the preset interval The timing of the output scan is therefore held to a regular interval varying very little which is an advantage for continuous analogue cont...

Page 71: ...Page 2 4 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 Figure 2 2 GEM80 400 Controller Operating Cycle...

Page 72: ...2 Operating Cycle Operation Phase This is a continuous cycle and is the normal condition of the controller During this cycle the processor will set the output data While this is happening the processo...

Page 73: ...de and data table RAM 2 A 16 bit checksum test of the following data areas source code object code V table P table and EPROM Note i CRC of operating system EPROM is checked at system power up ii Sourc...

Page 74: ...ad Outputs are set to values in output tables Controller watchdogs are open User program is scanned once when the program is single cycled Programming activity local or remote is active ESP Control an...

Page 75: ...atchdog trip where nnn user error code Examples of faults User Program CRC failure Watchdog Self test failure Recovery Mechanism Power Cycle 2 4 6 Fatal Shutdown Inputs are not being read Outputs rema...

Page 76: ...cycle on completion For further information the operation of the serial link is discussed in Chapter 4 2 6 Program Scan Times GEM80 400 Controllers operate on a repetitive I O scan and program executi...

Page 77: ...of nine components Scan Interval Tb Tw To Ti Tf Tc Tfip Ts where 1 Tb The time taken to execute all of the bit logic instructions e g and in the ladder program To calculate Tb count the number of bit...

Page 78: ...CONTROLLERS TECHNICAL MANUAL Page 2 11 Nvo Nbo Neo number of words of Verification Outputs to be scanned number of words of Basic Outputs to be scanned directly number of words of Basic Outputs to be...

Page 79: ...m the FIP data base and write produced data to it This is only applicable if the optional FIP interface is fitted and the FIP configuration special function is present in the user ladder program This...

Page 80: ...the controller automatically shuffles as the definitions are entered edited or deleted A print out facility lists the message formats in a numbered and readily understandable form Text messages edited...

Page 81: ...his time all outputs are frozen and inputs are ignored If compilation is successful the controller will run the modified program If not the controller will run the previous compiled program A message...

Page 82: ...table is cleared except for P0 to P149 These table locations include the configuration data for the serial links These sections of P table are not cleared because the GEM80 400 Processor Module may be...

Page 83: ...o the controller relating to address A0 0 B1 1 bit 1 of 16 bit word B1 is an output data table and depending on the result of executing the user program B1 1 is set to 1 or 0 and the I O equipment con...

Page 84: ...merical Manipulation 10 Block Instructions 11 Data Moving Instructions 12 Code Conversion 13 Serial Port Alphanumeric Input and Output 14 Output Functions 15 GEM80 400 Additional Special Functions Det...

Page 85: ...usive OR XOR Bit by bit XORing of 2 16 bit words 1 0 3 0 85 4 1 5 Exclusive OR group of words XORGRP T26 Bit by bit XORing of 2 groups of 16 bits words 2 3 See Note 1 Invert INV Inverts each bit of 16...

Page 86: ...ovides the logarithm to the base 10 of a value FP 1 102 Log to the base e LOGE S74 Provides the logarithm to the base e of a value FP 1 102 Pi PI S77 Provides Pi in FP 2 OR 1 2 1 Exponential EXP S84 R...

Page 87: ...rotation on a group of 16 bit words 2 3 See Note 14 Put bit PUTBIT T23 Allows setting and resetting of individual bits in groups of words 2 3 See Note 15 Shifts bits in words QSHIFT T27 Shifts bits o...

Page 88: ...2 1 96 Fill array FILL T17 Fill array with value 2 0 or 1 See Note 21 Put word PUTWORD T29 Indirect outputof word 2 1 96 Collate COLLATE T37 Collates random bits or words into a group of adjacent data...

Page 89: ...1 7 SEQGRP T111 Sequence Group 2 See Note 28 SR T112 SR Flip flop 1 2 75 RS T113 RS Flip flop 1 2 75 CLOCK S55 Real time clock 2 6 68 FIPCFG S145 FIP configuration FIP interface module required 2 See...

Page 90: ...dant on a number of factors and is impossible to predict 28 See later in chapter for examples of this function 29 5800 600 per channel 30 700 800 per block of 111 words 7 Qty of locations 31 900 500 p...

Page 91: ...Page 2 24 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 This page left intentionally blank...

Page 92: ...recompiled Constants which are derived by inspection of the output from LOCATE in a different program should not be used As a general rule LOCATE must be used every time an internal address is requir...

Page 93: ...The maximum number of data tables and instructions is fixed for each memory size i e there is no trade off between data tables and instructions 2 10 Program Development Programs can be developed prior...

Page 94: ...ample AND AND AND OUT G6000 W800 R50 G1 AND OUT Q2000 Q2000 Figure 2 6 Declaring Highest Address 2 11 3 Storing Programs As programming proceeds and especially when complete copies of the program shou...

Page 95: ...running in EPROM the data is stored in the following locations 9291 4024 FLASH Memory Module GEM 80 400 on board RAM Source for User Program YES NO Compiled User Program NO YES See Note 1 User Text Me...

Page 96: ...dule caused the failure the controller remains halted S0 remains unchanged The controller cannot be run until S0 is set to 0 Any IMAGEM Modules are restarted Program EPROM areas the on board FLASH EPR...

Page 97: ...will run WARNING The controller will automatically enter the RUN state when power is applied if ALL the following conditions are true A Flash EPROM module containing a valid user programme is fitted T...

Page 98: ...can be initiated For example F1 123 may be a shut down occurring because a limit switch signal has not been received Once this has been rectified G10 0 should be arranged to reset to zero and the cont...

Page 99: ...bit 2 in word 41 of the P table If we were only interested in the content of one bit of G1 for example bit 4 we would examine the data table address G1 4 and find that G1 4 1 However such a search is...

Page 100: ...d integer within the range 32 767 to 32 768 When bit 15 1 a negative number is represented and when bit 15 0 a positive number or zero is represented 2 13 2 3 Hexadecimal The numbers are to base 16 an...

Page 101: ...in the data tables When monitoring rungs floating point numbers are displayed to 2 decimal places The Program Operation section of this chapter gives more information on using GEM80 programming tools...

Page 102: ...elf where there is space only for 7 characters on the screen 2 13 5 Action of Clear Store on Data Tables The CLEAR STORE command has the following effects 1 Removes the ladder diagram program from mem...

Page 103: ...s Program Repetition Interval System Identification Codes Serial Link operational data signalling rate printer data etc Verification I O data STARNET FIP 150 NO NO NO P150 on Available for use in the...

Page 104: ...user to control the program scan repetition time and serial link operational data 2 Preset data values entered by the user for use in the program and addresses P150 upwards 3 Storage of Printer Text...

Page 105: ...rds Specifying 0 de configures the block and all subsequent non zero entries are ignored Specifying a negative value selects a file size of the absolute value of the number entered and indicates that...

Page 106: ...s to zero at FFFF 2 13 7 Real Time and Date This is generated from an integral real time clock The accuracy is better than one minute per month and the clock runs from the battery The integral calenda...

Page 107: ...s preset scan time F2 1 Set to 1 for one scan if recompile successful F2 2 Set to 1 if recompilation will occur on the current scan F2 3 Reserved F2 4 Battery condition Onboard battery low warning bit...

Page 108: ...Table 2 8 I Data Table Content Address Content Remarks I0 to I39 User control mode for serial port 1 I40 to I79 User control mode for serial port 2 I80 to I119 User control mode for serial port 3 2 13...

Page 109: ...area in bytes V53 to V57 Reserved for system usage V58 V table checksum V59 User program checksum V60 P table checksum V61 Rack Identification V62 Mode Switch position 0 halt 1 program 2 running V63...

Page 110: ...bit address and any data relevant to the instruction 2 14 1 5 Programming Rules Normal decimal hex entry procedures for bit address apply A retentive coil can only be the last element in a rung It may...

Page 111: ...Example Program SETIP MEMORY This rung sets S the retentive A1 0 G12 3 coil RESETIP MEMORY This rung R resets the A1 1 G12 3 retentive coil MEMORY This rung uses the G2 0 G12 3 G2 2 G3 0 memory to per...

Page 112: ...ladder program continues on the next rung i e no jump occurs Only forward jumps are permitted in a program It is permissible to have more than one jump instruction pointing to the same label but it is...

Page 113: ...d and compiled in the controller a compiler error is reported if a JUMP number or LABEL number exceeds the number range permitted in the controller or if a JUMP number is found with no matching LABEL...

Page 114: ...rogram 2 14 2 10 Cross Referencing on Ladder Printout The printout cross reference feature when selected prints the rung that will be jumped TO against each JUMP instruction and the rungs which jump t...

Page 115: ...INHIBIT signal is not applied a STEP is ACTIVE and produces ACTIONs ACTIONS The outputs from STEPs which drive the plant COMPLETE The status of a STEP when it has been ENABLED and the TRANSITION condi...

Page 116: ...a single STEP in a SEQUENCE together with the associated TRANSITION to the next STEP A sequence element can exist in the following states RESET STATUS Quiescent state ready for operation ENABLED STEP...

Page 117: ...itialised ENABLE internal Zm bit 6 Alternative to rung input X for ENABLING the step typically used during testing ON 1 ENABLE step If manually writing data to this bit the user must be particularly c...

Page 118: ...e the step is ENABLED rather than from STEP ACTION ON 1 Timer runs while step is ENABLED OFF 0 Timer runs only while STEP ACTION is TRUE Zm 2 Zm 3 TIMER INPUTS OUTPUTS TIMER REMAINING DURATION Zm 2 Ou...

Page 119: ...is used to HOLD the initiation of all STEPs in the GROUP by either the rung input X or by the internal ENABLE input This has the effect of holding the sequence ON 1 GROUP HOLD activated GROUP RESET T...

Page 120: ...configured to complete its step on the expiry of the timer Note The timer freezes when a STEP is ACTIVE and the STEP INHIBIT signal is true These diagrams are drawn for the case where all GROUP HOLD a...

Page 121: ...equences Group control of SEQELEM instructions within a program for such functions as reset and simulation is provided by the Sequence Group Special Function SEQGRP Use of SEQGRP Special Function The...

Page 122: ...SE01 1A Example Program for a Simple Sequence SE01 1 SE01 2 SE01 3 SE01 4 SQ SQ SQ SQ W100 W104 W108 W112 W116 0 This example uses mnemonics SE01 1 to SE01 4 for STEPs 1 to 4 of SEQUENCE number 01 St...

Page 123: ...ED STEP 5 is ENABLED by the COMPLETION of one of STEP 2 STEP 3 or STEP 4 whichever is COMPLETED first Subsequent COMPLETION of the other STEPs from 2 3 and 4 do not re ENABLE STEP 5 b SE01 1 SE01 2 SE...

Page 124: ...ued by using the STEP COMPLETE output of STEP 6 W120 15 similarly the SEQUENCE comprising STEPS A to H is continued using the STEP COMPLETE output of STEP D W212 15 Example Program Showing Conditional...

Page 125: ...TEPs 4 5 6 and 7 as a sub sequence for STEP 2 The INHIBIT TIMER input for STEP 2 W205 1 is set ON to disable the timer operation for STEP 2 as it is now composed of STEPs 4 5 6 and 7 which are themsel...

Page 126: ...comprises STEPs 1 2 and 3 of SEQUENCE number 01 The values of GROUP2 and RESET2 will determine the states of the same GROUP inputs as before to be used within the GROUP 2 sequence comprising STEPs 1 t...

Page 127: ...Preset values P200 0 DATA FOR STEP 1 P201 2 Mode for step 1 timer inhibited bit 1 ON P202 0 P203 0 Required Duration not needed since not used P204 0 DATA FOR STEP 2 P205 1 Mode for step 2 timed step...

Page 128: ...tools which support it Accuracy of Timing For accurate operation of the timer built into each SEQELEM instruction it is important for the user to arrange for the rung containing a SEQELEM instruction...

Page 129: ...2 Controller Architecture and Program Operation GEM80 400 Page 2 60 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 This page left intentionally blank...

Page 130: ...oller subrack there are two connectors at the right hand side of the upper backplane to allow additional I O subracks to be connected to the highways with ribbon cables 3 2 Fault Reporting and Detecti...

Page 131: ...cation I O transfer provides address data checkwords and data confirm words during the I O transfer Outputs are not written to the plant by the I O module unless the address data checkword sent by the...

Page 132: ...ing these parameters a blank table Table 3 14 has been provided at the end of this chapter which can be copied as required Caution Ensure that each module has a unique address or the system will not w...

Page 133: ...modules The I O subrack accepts 8 point modules in any slot as all slots are user addressable A decoder switch S1 or S2 selects the addresses for a group of four adjacent 8 point modules S1 selects a...

Page 134: ...Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Page 3 5 Table 3 3 shows how the switch settings control the slot addresses...

Page 135: ...Addresses Determined by Slot Position Slot No 8 7 6 5 4 3 2 1 Address 14 15 12 13 10 11 8 9 6 7 4 5 2 3 0 1 3 5 Addressing Additional Basic I O Modules Additional Basic I O Modules may be addressed u...

Page 136: ...11 10 10 11 11 10 10 6 13 13 12 12 13 13 12 12 13 13 12 12 7 15 15 14 14 15 15 14 14 15 15 14 14 bits 8 15 0 7 8 15 0 7 8 15 0 7 8 15 0 7 8 15 0 7 8 15 0 7 3 5 1 2 16 Point Modules 16 point modules l...

Page 137: ...ontroller can handle up to 1 024 words on the Verification I O Highway which can contain either 16 384 ON OFF states 1 024 numeric values range 32 767 or 32 768 or any mixture The controller also has...

Page 138: ...sic I O Highway Each 8191 provides up to 512 points 32 words of Basic I O 3 8 1 Verification I O Expander 8191 4004 3 8 1 1 Introduction The 8191 4004 Verification I O Expander Module fits into the ri...

Page 139: ...are accessible without removing the plastic protective cover They are in a group of eight bits 0 7 and a group of four bits 8 11 When a switch is in the ON position that bit is a logical 1 Figure 3 2...

Page 140: ...GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Page 3 11 Figure 3 3 shows the Range Switches set to 19 25 decimal If the address of the module is set to 320 the module will respond to addresses within t...

Page 141: ...ification I O address range up to 1039 e g if the base address was set to 1010 and the range to 1F 31 decimal the last two configured addresses 1040 and 1041 would be outside the Verification I O addr...

Page 142: ...bit Under normal operation all the F table locations monitoring I O operation are at zero If any of the strobe or data lines for a particular ribbon are not working correctly the fail bit and the faul...

Page 143: ...71 240 320 327 272 576 583 304 832 839 209 72 79 241 328 335 273 584 591 305 840 847 210 80 87 242 336 343 274 592 599 306 848 855 211 88 95 243 344 351 275 600 607 307 856 863 212 96 103 244 352 359...

Page 144: ...on of the plant IN THE EVENT OF F TABLES BEING SET THE ASSOCIATED INPUTS DROP TO ZERO AND THE ASSOCIATED OUTPUTS FREEZE IT IS THE USER S RESPONSIBILITY TO TAKE ANY NECESSARY ACTION WITHIN THE PROGRAM...

Page 145: ...Page 3 16 ALSPA GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Issue 3 04 99 Figure 3 5 I O Subrack Connected to GEM80 400 Controller Part 1...

Page 146: ...Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Page 3 17 80 400 Figure 3 5 I O Subrack Connected to GEM80 400 Controller Part 2...

Page 147: ...Page 3 18 ALSPA GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Issue 3 04 99 Figure 3 6 Typical Verification I O System A B 0 to 15...

Page 148: ...of 8 point modules form one 16 bit word so each pair of 8 point modules must be either Input modules or Output modules Each 16 point module provides one word of I O and thus each slot can be addressed...

Page 149: ...digits see Figure 3 2 The range of the address window is set by the two hexadecimal switches SW1 and SW2 with SW1 giving the least significant digit see Figure 3 3 Expander No Base Address 151 SW4 00...

Page 150: ...discrete wiring and is not available from the ribbon cables 3 10 2 I O Power Consumption When configuring a system the logic power consumption of the I O modules must be determined The power requireme...

Page 151: ...4 3 2 1 1 2 3 4 5 PSU spare Module 8239 Total mA 9017 capacity Current at 5V 2500 12000 Current at 15V 500 8000 Table 3 12 may be used to calculate the current consumption for a 12 slot I O subrack T...

Page 152: ...quirement through discrete wiring The Verification I O Modules require a 5V supply This is not available on the Verification I O ribbon The 5V is therefore supplied either from the power module in the...

Page 153: ...Page 3 22 ALSPA GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Issue 3 04 99 All wiring is VERY CLEAN see Cable Routing and Segregation Chapter 7...

Page 154: ...the I O ribbon cables are exceeded additional I O subracks should be connected to the controller power supply using discrete wires The power supply wiring is connected to TB1 3 Standard or TB3 4 Enha...

Page 155: ...n the size of the wires used The terminals on the subracks can accommodate wire sizes up to 2 5mm but 1 0 or 1 5mm wire sizes should be adequate 3 10 6 Connecting an External Power Supply 3 10 6 1 Ext...

Page 156: ...ppropriate action must then be taken by the user 3 10 7 Powering the Verification I O Expander Module 3 10 7 1 Powering via Ribbon Cables Power to I O equipment may be supplied through Verification I...

Page 157: ...erminal for 15V 4 Push on Terminal for 0V Figure 3 10 Powering Verification I O Expander Module from Power Supply Module When 15V power is supplied from an external 15V power pack LK5 on the 8191 Veri...

Page 158: ...d Verification I O Highway These cables connect to the Basic I O or Verification I O Highway sockets on the controller subrack and then to each item of Basic or Verification I O equipment in turn with...

Page 159: ...n standard ribbon cables or damage to any equipment caused by the connection of faulty non standard ribbon cables 3 12 Length Limits for 26 Way Basic I O Ribbon Cables The Basic I O equipment draws cu...

Page 160: ...ocks connect is high all I O modules are fitted Connections for this are shown in Figure 3 13 For the circumstances where the I O subrack is not completely full of modules a shorting link in the form...

Page 161: ...Page 3 30 ALSPA GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Issue 3 04 99 Figure 3 13 Typical Module Interlock Circuit...

Page 162: ...er module for access Maximum wire size 2 5mm Notes 1 All wiring is DIRTY category 2 Maximum size of wiring that can be terminated at INT and INT terminals is 2 5mm 3 15 Output Enable Modules Some outp...

Page 163: ...16 Figure 3 15 illustrates the use of GEM80 15V power supplies and Figure 3 16 illustrates the use of external 15V power supplies Resistors R7 and R8 or R14 and R15 should be removed as indicated The...

Page 164: ...ed Note 2 The enable terminals TB2 2 and TB2 1 EN and EN respectively on the 8 slot I O subrack and Standard Controller Subrack are TB1 12 and TB1 13 respectively on the 12 slot I O subrack and TB2 1...

Page 165: ...hanced Controller follows refer to the Standard Controller section earlier in this chapter A system has a requirement for a combination of Basic and Verification I O Modules There are six Verification...

Page 166: ...Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Page 3 35 Figure 3 17 GEM80 400 Enhanced Controller and I O System...

Page 167: ...00 200 200 1700 1000 6780 12000 5220 Current at 15V 450 450 40 40 500 1480 8000 6520 Rack 1 Slot No 12 11 10 9 8 7 6 5 4 3 2 1 Module 8163 8166 8163 8165 8177 8178 8178 8178 8164 8164 8164 8164 Total...

Page 168: ...Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Page 3 37 Current at 15V Rack 4 Slot No 12 11 10 9 8 7 6 5 4 3 2 1 Module Total mA Current at 5v Current at 15V...

Page 169: ...3 2 1 1 2 3 4 5 Total PSU spare Module 8239 mA 9017 capacit y Current at 5V 2500 12000 Current at 15V 500 8000 Rack 1 Slot No 12 11 10 9 8 7 6 5 4 3 2 1 Module Total mA Current at 5v Current at 15V R...

Page 170: ...Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLER TECHNICAL MANUAL Page 3 39 This page left intentionally blank...

Page 171: ...ble GEM80 programming tool such as Gemesys 3 or a printer 4 Communication with and connection to intelligent serial devices and Central Highway Modules such as GEMLAN D and STARNET The GEM80 400 Contr...

Page 172: ...ports can be added using Fast I O Serial Communications Modules and or STARNET Modules See the relevant User Information Sheets for connection details 4 1 1 Connecting Serial Ports 1 and 2 Serial Port...

Page 173: ...ome GEM80 controllers other than the GEM80 400 provide a form of RS422 serial links These may be connected via a ribbon cable to a 8587 4003 Termination Unit to convert to RS485 and thus allow communi...

Page 174: ...T457 The GEM80 400 Enhanced Controller may be additionally fitted with STARNET GEMLAN D or Fast I O communications facility Further details of these facilities are given later in this chapter and in...

Page 175: ...signal 4 3 1 Point to Point Serial Link A point to point serial link between two controllers may be implemented using RS232 or RS485 The serial communication port of one controller is set up as a con...

Page 176: ...sible though data can be exchanged between tributaries via the control port provided that the facility exists in the user program of the controller having the control port Figure 4 7 shows an example...

Page 177: ...TROLLERS TECHNICAL MANUAL Page 4 7 Figure 4 6 Multi drop Serial Link GEM80 400 CONTROLLER CONTROL PORT TRIBUTARY PORT ADDRESS 0 GEM80 400 CONTROLLER TRIBUTARY PORT ADDRESS 1 GEM80 400 CONTROLLER TRIBU...

Page 178: ...out unit which breaks a 9 way D type connection into screw terminals is a KLIPPON RD9F Cat No 068356 It should be noted that the drop of the cable must be limited to 2 metres 4 3 4 Using the Printer P...

Page 179: ...Issue 3 04 99 ALSPA GEM 80 400 SERIES CONTROLLERS TECHNICAL MANUAL Page 4 9 This is achieved by fitting a link in the Printer Programming cable connector see Figure 4 8 for...

Page 180: ...Port Port 3 Connections The Printer Programming port connector is a 15 way female D type socket connector with threaded retention pillars The pinouts are as shown in Figure 4 8 Pin Connection 1 RX Ext...

Page 181: ...eristics RS232 RS485 ASCII character set equivalent to IS0 7 1 start bit 7 or 8 character bits optional parity none odd or even and 2 stop bits Parity options configurable by preset data for odd even...

Page 182: ...one for output Data can only be written to the output buffer and read from the input buffer by means of GEM80 Special Functions You cannot otherwise access these buffers from your ladder diagram progr...

Page 183: ...buffer in addition to the input cyclic buffer All received characters are initially stored in the line buffer They are only transferred to the input cyclic buffer when a 0D CR is received and until th...

Page 184: ...line buffer are re output preceded by CR LF plus NULs if the cursor is not already at the left hand margin followed by the echo of any characters which were entered during the output 4 4 2 3 Free For...

Page 185: ...d the appropriate fault code is generated by the GEM 80 Special Function Overflow of the input buffer can occur resulting in the oldest data being overwritten and lost See Table 2 5 E tables for more...

Page 186: ...executed Messages are entered in a manner which is intended to be similar to the way they will be displayed when used by PRINT Fixed text is enclosed by quotes format definitions employ a pictorial r...

Page 187: ...e as follows E Stands for Exit Terminates the editing session and causes the programming tool to return to initial selection H Stands for Help Displays a list of the available commands on the programm...

Page 188: ...h is a power of ten the indicates division and the multiplication Each scaling value may be separated from the others by an optional comma End of line markers may be included in the message by typing...

Page 189: ...er of tables to be transmitted free running mode only 0 to 32 for fixed data tables 0 to 128 for flexible data tables P15 to P29 P35 to P49 Unused J0 to J511 J512 to J1023 J table Data received by the...

Page 190: ...a tables with message length limited to a maximum of 32 words or with flexible data tables that allow a maximum message length of 128 words per route subject to a total J K table allocation of 512 wor...

Page 191: ...J K0 to 31 J K32 to 63 J K64 to 95 J K96 to 127 J K512 to 543 J K544 to 575 J K576 to 607 J K608 to 639 Tributary address 0 Tributary address 1 Tributary address 2 Tributary address 3 J K128 to 159 J...

Page 192: ...ddress 4 bit 13 Receive flag tributary address 5 bit 14 Receive flag tributary address 6 bit 15 Receive flag tributary address 7 I1 I41 Tributary 0 Tx and Rx message length bits 0 to 7 Tx 0 to 32 bits...

Page 193: ...0 to 128 bits 8 to 15 Rx 0 to 128 I2 I42 Route 1 Tx and Rx message length bits 0 to 7 Tx 0 to 128 bits 8 to 15 Rx 0 to 128 I3 I43 Route 2 Tx and Rx message length bits 0 to 7 Tx 0 to 128 bits 8 to 15...

Page 194: ...8 Configuring an ESP Control Port Using Flexible Data Tables Port 1 Port 2 Contents P10 P30 Baud rate 110 to 19 200 P11 P31 3 Flexible ESP Control Port Mode P12 P32 0 Free running Mode 1 User control...

Page 195: ...a Tables When an ESP control port is configured for flexible data tables P11 31 3 the tables are assigned dynamically according to the two byte values set in P14 to P21 P34 to P41 The number of tables...

Page 196: ...cated in the preset data to be in use and attempts a J K exchange transmitting the quantity of locations requested in the P table If a valid reply is not received after the system of retries has been...

Page 197: ...GEM80 400 control port provides the option of increasing the standard time out values This is achieved by setting the signalling rate to the negative of that required e g to select extended time outs...

Page 198: ...ble configuration shown in Table 4 10 The facility allows direct control of GEMSTART CCUs by a GEM80 400 Controller through the RS485 serial link ports Using a suitable GEM80 programming tool such as...

Page 199: ...y on RECOMPILE no need to power down P17 which determines the configuration to use if there is a configuration conflict can be changed with a suitable GEM80 programming tool such as Gemesys 3 and take...

Page 200: ...e user specified tables must be allocated in contiguous locations with 5 words per GEMSTART CCU plus 5 words to hold the Processor control information when P11 6 GEMSTART CCU Mode or 10 words per CCU...

Page 201: ...tional switching A suitable GEM80 programming tool such as Gemesys 3 must be used since it has a selectable signalling rate and the slow signalling rate necessary for long distance serial links can be...

Page 202: ...s 1 and 2 9 way D type connector Port 3 15 way D type connector 4 10 3 Segregation Ensure that 600mm 2 feet exists between the serial link cabling and electrically dirty wiring Chapter 7 of this manua...

Page 203: ...rotocol For full details of the STARNET Module including more information on operation software and connections see the STARNET User Information Sheet Publication No T464 and refer also to Chapter 5 o...

Page 204: ...quired Max No Permitted in Subrack 256K RAM without arbiter 8272 4004 1 5 Fast I O Equipment Ordering Code No of Central Highway Slots Required Max No Permitted in Subrack FAST I O Driver Module 8300...

Page 205: ...supplies each slot occupied by a Central Highway Processor Module with a Unit ID the value of which is indicated by Figure 5 1 This Unit ID is used by the system to differentiate between modules of t...

Page 206: ...Module may be used to supply the system with IMAGEM memory additional to the 64K supplied by the GEM80 400 Processor Module This memory is used by IMAGEM Modules installed in the rack to store format...

Page 207: ...cessor to detect module failure as status linking is not supported by GEM80 400 systems 5 5 Summary 1 The default configuration of a GEM80 400 Enhanced system is given by Figure 5 1 2 Configurations t...

Page 208: ...Memory Example Suppose that a system requires 1 GEMLAN D Module 2 IMAGEM Modules and some Off line RAM Modules required 1 off 8279 400x GEMLAN D 2 SLOT 1 Maximum permitted 2 off 8284 400x IMAGEM 2 SLO...

Page 209: ...TROLLERS TECHNICAL MANUAL Issue 3 04 99 Where G0 GEMLAN D accessed as GEMLAN D 0 G1 GEMLAN D accessed as GEMLAN D 1 I0 IMAGEM 0 I1 IMAGEM 1 R0 RAM Module used for OFF LINE memory R01 RAM Module split...

Page 210: ...ion to IMAGEM The IMAGEM Processor Module is a single width video output processor module The IMAGEM Video System accesses the controller s data tables for display data and for control information The...

Page 211: ...GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 Figure 5 2 IMAGEM Module Note The Signal Ground S G must be connected to a clean ground to provide a suitable ground connection for the fro...

Page 212: ...IMAGEM Display Language which uses easily remembered English keywords Apart from instructions affecting the presentation e g sizes and colours each format will normally consist of text including both...

Page 213: ...e sync output Figure 5 3 illustrates the IMAGEM connections to be made on the upper backplane of the Enhanced Controller subrack Figure 5 3 IMAGEM Connections on the Enhanced Controller Subrack Upper...

Page 214: ...its associated secondaries slaves The primary device controls all activity on the link allowing the secondaries to communicate only when given permission The STARNET Module which may be fitted in a GE...

Page 215: ...Page 5 12 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 Figure 5 4 STARNET Module...

Page 216: ...ions to be transmitted at high speed between GEM80 controllers and DECnet devices via an ETHERNET Local Area Network LAN Figure 5 5 illustrates a GEMLAN D Module Network communications between GEM80 c...

Page 217: ...Page 5 14 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 Figure 5 5 GEMLAN D Module...

Page 218: ...ndustrial Controls Ltd 5 11 4 Operation Note It must be noted that unlike most other GEM80 equipment the operating temperature of GEMLAN D is 0 to 50 C and not 0 to 60 C Therefore a GEM80 400 Enhanced...

Page 219: ...Standard Controller The Fast I O equipment itself is detailed in GEM80 Product Data Sheets and User Information Sheets note particularly its use in conjunction with GEMSTART CCU The wide choice of eq...

Page 220: ...Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Page 5 17 1 Module Function Label 2 Module Ordering Number 3 Ejection Handle Figure 5 6 Fast I O Driver...

Page 221: ...Driver Module Other Fast I O Modules may be installed into a separate Fast I O subrack Central Highway Slot 1 is the only slot that can be configured to use a Fast I O Driver Module Slot 1 may be con...

Page 222: ...Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Page 5 19 Twisted pair between Subracks R0 PL7 Pin 10 0V R1 U06 W20...

Page 223: ...nt two wires connected to TB3 6 The additional Fast I O Subrack must have the safety earth connected to a suitable earth The Safety Earth and Signal Ground wiring should be connected using 2 52mm 5 12...

Page 224: ...4 to 735 22 15 I O 736 to 767 23 16 Subrack 768 to 799 24 17 800 to 831 25 18 832 to 863 26 19 864 to 895 27 20 896 to 927 28 928 to 959 29 960 to 991 30 992 to 1023 31 Fast I O addresses are included...

Page 225: ...9018 and the 9032 Power Modules When a 9017 4001 Power Supply Module is fitted in earlier GEM80 400 Enhanced Controllers the incoming ac power supply must be connected to the terminal block as illustr...

Page 226: ...Page 6 2 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 Figure 6 1 Power Input Terminal Block Figure 6 2 Filter Assembly for 9017 4001 Power Supply...

Page 227: ...25 0A 5V 8 0A 15V 9017 4010 12 0A at 5V 6 0A at 15V 7 0A at 5V 2 0A at 15V The current available from the 15V rail may be increased up to a maximum of 5A by trading off 2A at 5V for every additional 1...

Page 228: ...ms ride through on a nominal 24V at full load 50ms ride through on a nominal 48V at full load Shut down after ride through time Automatic recovery when the supply resumes 20ms ride through on 110V or...

Page 229: ...n 8917 Power Module Comments 8918 Power Module Comments Nominal Power Input 110 240V ac 50 60Hz Single phase 110 220V dc Single range no adjustment necessary 24 48V dc Single range no adjustment neces...

Page 230: ...ge falls 5 below nominal value Over voltage shutdown Shutdown if any output voltage rises 20 above nominal value Shutdown if any output voltage rises 20 above nominal value Self test Under voltage det...

Page 231: ...the current consumption is split approximately in half into 2 x 450mA See also any relevant User Information Sheets for further details of current consumption 6 3 2 Controller Power Distribution 1 Al...

Page 232: ...032 Power Supply Modules as shown in Figure 6 3 AC power input is via the ac power connector which is supplied loose with the equipment Line neutral and earth connections are as marked on the connecto...

Page 233: ...cket 6 Output Control Switch 7 Combined AC Power Input AC fuse holder and AC voltage selector Figure 6 3 Power Supply Module AC and DC Connections Figure 6 4 Signal Ground and Safety Earth Connection...

Page 234: ...ut 6 4 3 AC and DC Fed Power input connections for ac and dc fed controllers are shown in Figure 6 3 It is necessary to set the ac voltage selector as required There is an internal diode OR which allo...

Page 235: ...power supply which is connected by means of a pair of twisted wires to the rear of the controller subrack The connections to the subrack are made via two Faston connectors which are located at the bot...

Page 236: ...Page 6 12 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 Figure 6 7 Fast I O Power Connections for GEM80 400S Controllers...

Page 237: ...and are retained by two sliding strips built into the subrack which lock the modules in position by engaging slots at the top and bottom of the modules Dimensions for the subrack are illustrated in F...

Page 238: ...hape 7 2 1 Front Flange Mounting Note Front flange mounting requires a flat surface at the rear of the mounting panel To assist with the mounting procedure threaded inserts have been fitted in the sub...

Page 239: ...most fixing holes on the mounting panel leaving at least 10mm of thread projecting 2 Offer the subrack assembly up to mounting panel allowing the screw heads to pass through the keyhole shape The subr...

Page 240: ...of the cubicle and leave adequate space for plant cable glanding 2 Equipment or wiring which carries signals which could contain electromagnetic noise from the plant is termed dirty Equipment or wire...

Page 241: ...GEM80 400 7 Installation Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Page 7 5 Figure 7 2 Typical GEM80 Single Cubicle Layout...

Page 242: ...f a suitable GEM80 programming tool such as Gemesys 3 2 Access to control switches 3 Viewing indication devices 4 Removal and replacement of modules 7 4 5 Access Requirements 1 Access is required to t...

Page 243: ...hway Modules and RAM cards 6 Serial Ports 1 and 2 and the Printer Programming Connection Port are all situated at the front of the 8239 Processor Module 7 4 6 Heat Dissipation of I O Modules I O equip...

Page 244: ...noise problems GEM80 interconnecting cables are categorised into groups and these separate groups must be run physically separated by at least the distances given in Figure 7 5 Figure 7 5 Wiring Segr...

Page 245: ...is connected See Figures 6 4 6 5 and 6 6 for the earthing arrangements Safety earth cable must be a minimum of 2 5mm green yellow insulated wire and must be fitted in accordance with the segregation r...

Page 246: ...tem logic 0V is classified as very clean it should be run directly from the 0V connection on the controller subrack to the signal ground bar Minimum wire size should be 1 5mm run as a VERY CLEAN wire...

Page 247: ...ther however wires falling into different groups cannot be run together though paths may cross at right angles Wires of different groups must be spaced apart by at least the distance shown in Figure 7...

Page 248: ...reduced to 90mm for cables enclosed in conduit or 180mm under other conditions 7 6 2 2 Basic and Verification I O Ribbons These should not be run outside the cubicle but where this is impracticable u...

Page 249: ...t of modules Pre formed cable See Product Data Sheets Termination rail positioned to suit the installation Fast I O Termination Panels Ribbon cable connector backplane located at rear of subrack Up to...

Page 250: ...correct positions in the subrack ensuring that they are all fully inserted 4 Move the top slider toward the left until the pointer is opposite the closed symbol 5 Move the bottom slider toward the ri...

Page 251: ...e cable next to the connector which has a write on area for identifying where it connects to and also other information see Figure 7 8 for details If extra labels are required they are available from...

Page 252: ...Page 7 16 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 This page left intentionally blank...

Page 253: ...nual and most important checked out the operation of these circuits see the Safety Circuits Checks section later in this chapter Plugged in all modules taking adequate care about how you handle them I...

Page 254: ...procedure by cutting corners or you ll land yourself with problems The basic principle is to start off with a small amount of equipment check it out thoroughly and then when you re 100 certain that it...

Page 255: ...rgency stop push button which you can use as a panic button sited close to where you are working If there isn t one there you may want to install one Connect it in series with the rest of the safety c...

Page 256: ...of each module agrees with that shown on the lower subrack label strip 4 Power up the programming tool 5 Connect the programming tool and any peripheral equipment e g printer Connect the programming...

Page 257: ...STORE command from the programming tool ii Check the reply to see if the link failure has cleared If so proceed with the checks at b below iii If the link failure is still present check that the prog...

Page 258: ...ral Highway Module and commission the system as given in the Processor Module Checks section Repeat this procedure for each Central Highway Module to be incorporated Refer to the relevant User Informa...

Page 259: ...the address and range switches are correctly set up on the 8191 Verification I O Expander for the particular inputs you want to check See Chapter 3 for the addressing principles 2 Check the address s...

Page 260: ...input signal or where this is not possible disconnect the transducer and simulate its output with a battery and potentiometer 2 Check that a variation in each analogue input signal is registered as a...

Page 261: ...gram the GEM 80 starts scanning the Fast I O If you have plugged in just the Fast I O Driver Module but no Fast I O Modules then once scanning starts you will get a Fast I O failure error message 6 Se...

Page 262: ...ent if Gemesys 3 is not your programming tool check each I O output in turn by writing to the B table addresses for Basic and Verification I O and D table for Fast I O addresses and checking that the...

Page 263: ...trols Ltd refer to Chapter 10 of this manual for ordering codes 8 15 Loading the User Program When the power supply and input and output checks have been completed satisfactorily the user program can...

Page 264: ...a printer or VDU include the PRITEXT GEM 80 Special Function in the program The Printer port must be preset with the following data for the printer in use the baud rate bit s the character format quan...

Page 265: ...amming Manual for an introduction to ESP serial links For further details on these printer ports see the GEM 80 Serial Communications Manual Publication No T457 8 17 Fitting a Memory Expansion Board t...

Page 266: ...User Instructions sheet contained with the Interface should be followed The same precautions are required as for fitting a Memory Expansion Module 8 19 A Few Final Comments In the preceding paragraph...

Page 267: ...GEM80 400 8 Commissioning Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Page 8 15 This page left intentionally blank...

Page 268: ...with spare modules These spare modules may be stored powered up i e functional spares It is recommended that all spare modules are powered up every 9 months to reform any electrolytic capacitors whic...

Page 269: ...e battery warning LEDs of any Central Highway Modules which may be fitted If an LED is lit replace the battery of that module as instructed in the User Information Sheet or Manual relevant to that mod...

Page 270: ...ed crimp to the positive terminal and the other lead to the negative terminal 5 Slide the battery back into position and close the cover 6 Dispose of the old battery as detailed in Chapter 1 GEM80 Bat...

Page 271: ...am execution while the GEM 80 is running subject to observing the safety precautions detailed in Chapter 1 of this manual With a suitable GEM80 programming tool such as Gemesys 3 connected and the app...

Page 272: ...the following indications Run System running Halt System halted nnn Fault shutdown nnn error number nnn User watchdog trip nnn user error code Test Full system self test TRun Run Test Inputs THlt Hal...

Page 273: ...Page 9 6 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99...

Page 274: ...105 Basic I O ref Error at instruction data Same word referred to as both input and output e g cannot refer to A0 and B0 in same program Reference over table limit Words must be either input or output...

Page 275: ...ion calls 113 Reference over table limit Error at instruction X rung Y Attempt to read write from non existent location in a fixed sized table Alter instruction to be within the limits 117 Illegal L r...

Page 276: ...SERIES CONTROLLERS TECHNICAL MANUAL Page 9 9 Code Fault Message Possible Causes Recommended Recovery 124 Invalid Instruction encountered Error at instr X rung Y User program has become corrupted Repl...

Page 277: ...VALUE either constant or table reference to follow it Insert the appropriate VALUE 130 No value at end of instruction Error near instruction X rung Y The last instruction has been reached before the V...

Page 278: ...ly be forwards 143 LABEL number data exceeds maximum at instruction X rung Y Maximum LABEL number is 15 Reduce LABEL number 144 JUMP number data exceeds maximum at instruction X rung Y Maximum JUMP nu...

Page 279: ...ions with COUNT and DELAY GEM80 Special Functions This checking ensures that if a VALUE is required it is present and of an acceptable type e g write enabled data table 6 Checking that there is a STAR...

Page 280: ...s e g C0 and D0 C32 and D32 and so on When compilation is attempted the program will not run if an invalid Fast I O address is used because of lack of response from the invalid address and a diagnosti...

Page 281: ...ER REMOVED WHILE PROGRAM IN A CHANGED STATE As part of the self test procedures which the controller undertakes there is a check that there has not been any alteration to program instructions and data...

Page 282: ...tem Could be caused by turning power off during compilation or faulty processor module It may be a flat battery but battery warning should occur first Power off on and reload If problem persists suspe...

Page 283: ...to program Set protect switch to PROG position and try again 627 FLASH EPROM not present or faulty The Processor cannot see a FLASH EEPROM memory sub board Fit a FLASH EEPROM sub board Replace FLASH...

Page 284: ...e fit and switch to EPROM 640 Failed to Erase EPROM memory FLASH EPROM memory sub board cannot be erased Replace FLASH EEPROM sub board 641 Failed to Program EPROM memory FLASH EPROM memory sub board...

Page 285: ...e Failed processor module Substitute spare processor module and sub board if fitted 708 Watchdog test failure Status d State d Suspect failed processor module Could be a faulty backplane but more like...

Page 286: ...Faulty connection cable short faulty I O module or faulty processor module Investigate connections and referenced I O device If problem persists substitute spare processor module and lastly spare subr...

Page 287: ...t message If problem persists substitute spare processor module and sub board if fitted Wherever is shown the number displayed when the fault occurs should be noted and Customer Support contacted 9 9...

Page 288: ...Possible Causes Recommended Recovery 806 IPC timeout to data Refer to 717 Refer to 717 807 Task i IPC error data Refer to 717 Refer to 717 808 Processor timeout data Refer to 717 Refer to 717 809 Chic...

Page 289: ...ser Program not compiled 921 Transmit timeout on serial link data 922 Software watchdog trip 923 Too many interrupt levels defined 924 Organiser interrupt timeout inter processor 925 Floating Point Un...

Page 290: ...on failure 976 FIP Medium invalid error x 977 FIP RAM Test failure error x 978 FIP BA Start error no x 979 FIP BA Stop error no x 980 FIP Hardware Software incompatibility 981 FIP Delete BA macro cycl...

Page 291: ...to F69 Serial link diagnostics for Serial Port 3 F70 to F129 Serial link statistics See the Link Statistics section of this chapter F70 to F89 Serial link statistics for Serial Port 1 F90 to F109 Seri...

Page 292: ...F30 10 Last message on route 2 was truncated F10 11 F30 11 Last message on route 3 was truncated F10 12 F30 12 Last message on route 4 was truncated F10 13 F30 13 Last message on route 5 was truncate...

Page 293: ...the three serial ports is allocated 20 F tables for Serial Link Statistics as follows Port 1 F70 to F89 Port 2 F90 to F109 Port 3 F110 to F129 The first two statistics for each port are in two locati...

Page 294: ...Incoming message too large for bu F78 F98 F118 Number of transmit data errors F79 F99 F119 Number of stuffing errors F80 F100 F120 Number of ENQs received Requests for a resend F81 F101 F121 Mode erro...

Page 295: ...ardware errors F75 F95 Time outs F76 F96 CRC errors F77 F97 Data errors F79 to F89 F99 to F109 Not used 9 15 I O Statistics There are 2 bits of statistics per I O address starting with F200 0 and F200...

Page 296: ...0 SERIES CONTROLLERS TECHNICAL MANUAL Page 9 29 The majority of the locations in the V table are for system internal functions and have no significance for the user However a few are useful and these...

Page 297: ...ring this section of P table is that GEM80 400 Controllers may be programmed either from the front port of the processor or remotely via one of the serial ports Loss of data about the serial port conf...

Page 298: ...9 Intermittent Tripping Problems GEM80 equipment is normally reliable in operation provided that it is installed in accordance with the guidance given in Chapter 7 of this manual If the equipment does...

Page 299: ...mware update mode is located near the back of the board in the centre between the two edge connectors It should be set to the PROG position for firmware update mode and returned to NORM position the n...

Page 300: ...Issue 3 04 99 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Page 9 33 GEM80 Customer Support Telephone 44 0 1782 781111 Fax 44 0 1782 781112...

Page 301: ...quest but when PCBs are repaired by the user ALSTOM DRIVES CONTROLS cannot accept any responsibility for faults which may arise Faulty modules or units for repair should be returned in packing which i...

Page 302: ...870 4115 12 slot 24 48V dc 12 8870 4114 The above Fast I O Subracks are for optional use with GEM80 400 Enhanced Controllers where Fast I O Modules are required Depending on the quantity of Fast I O M...

Page 303: ...M80 400 Enhanced Controller Module Type Function Slots Used Equipment Called up by Ordering Code Ordering Code IMAGEM Processor See Note 2 For displaying data taken from the controller s data tables o...

Page 304: ...22 4001 Blanking Panel Double 8122 4002 Serial Link Termination Unit providing terminals for one RS485 port 8587 4003 RS232 to 20mA converter externally powered 8975 0000 10 4 Spares Item Ordering Cod...

Page 305: ...M80 400 SERIES CONTROLLER TECHNICAL MANUAL Issue 3 04 99 10 4 1 Replacement Battery Suppliers ALSTOM DRIVES CONTROLS West Avenue Kidsgrove Stoke on Trent Staffordshire ST7 1TW Tel 44 0 1782 781111 Fax...

Page 306: ...rom these tests is stored in an area of memory known as the F table and diagnostic messages are sent to the screen of a suitable GEM80 programming tool such as Gemesys 3 when connected to a processor...

Page 307: ...Safety Earth Connections Figure 11 1 Location of Safety Earth Studs Safety earth studs are located on the subrack side panels at either end of the subrack The equipment must be earthed by a secure saf...

Page 308: ...anced Controller Figure 11 2 Watchdog Contact Terminals 11 3 1 Typical Watchdog Circuits Figure 11 3 shows an example of a typical watchdog safety circuit The input equipment will be energised when th...

Page 309: ...GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 Figure 11 3 Typical Watchdog Circuit 11 3 2 Watchdog Contact Ratings 11 3 2 1 Circuit Two series connected volt free contacts are provided...

Page 310: ...ontroller Note The key switch can be used to prevent unauthorised modification of the user program if the key switch is in the Halt position the program cannot run 11 5 Power Up Conditions Whenever th...

Page 311: ...y should fail while the controller is powered down the controller automatically comes up in RUN status the next time it is powered up as for a system without a battery To prevent this happening set th...

Page 312: ...ded supplier CAUTION Following problems with the termination of ribbon cables the cable manufacturers advise that ALL RIBBON CABLES ON REELS MUST BE STORED ON END Flat storage of these reels leads to...

Page 313: ...ent are normally made up for the customer by Cegelec Industrial Controls Ltd For the customer wishing to install his own ribbon cables the procedure detailed here should be followed A5 1 Mechanical Po...

Page 314: ...base plate ensuring that metal locking clips enter slots in cover see Figure A 2 c Insert cable between cover and base plate WITH END OF CABLE FLUSH WITH EDGE OF BASE PLATE Note Ensure that coloured...

Page 315: ...4 Base plate 5 Cover Figure A 2 Cable End Connectors Fitting of Cable and Cover e Using T B Ansley hand tool fitted with die press the cover down ensuring that the cable does not move so that contact...

Page 316: ...Issue 3 04 99 ALSPA GEM80 400 SERIES TECHNICAL MANUAL Page A 5 2 1 1 Cover 2 Base plate Figure A 4 Clamped Cable...

Page 317: ...te ribbon cable label for I O assembly as detailed in Chapter 7 of this manual g Push the strain relief down until the clips lock into the cover indicated by a small click Figure A 6 shows the complet...

Page 318: ...hat the amount of cable is sufficient to complete the length of run 2 When using twisted pair cable termination can only be made in the centre of flat sections a Pass free end of cable through slot in...

Page 319: ...n mark Figure A 8 Cable Middle Connectors Fitting of Strain Relief A 5 4 Right Angled Bends in Cable 1 Where ribbon cable has to be run flat with a right angled bend the cable can be folded in one of...

Page 320: ...A GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Issue 3 04 99 Figure A 10 Right Angled Bend Double Fold A 5 5 Fitting Ribbon Cable Label The label is wrapped around the ribbon cable as shown in Figure...

Page 321: ...13 1 14 1 21 2 1 2 36 3 21 4 29 5 1 5 2 5 3 5 4 5 5 5 6 5 10 5 12 5 14 5 17 7 7 8 2 8 6 9 2 9 20 10 2 cleaning 1 2 Commissioning 1 2 8 1 8 2 communication 1 1 1 2 1 6 1 21 2 1 2 6 2 9 2 10 2 29 2 32...

Page 322: ...2 4 4 4 25 4 29 5 1 5 3 5 4 5 5 5 6 5 9 5 10 5 12 5 14 5 15 5 17 5 18 6 1 6 7 7 1 7 7 7 7 8 2 8 6 9 2 9 10 9 11 10 1 10 2 11 3 Environment 1 1 1 2 1 22 7 7 9 28 environmental 1 1 1 22 7 7 9 28 ESP pro...

Page 323: ...h 1 3 2 38 modules 1 1 1 2 1 3 1 5 1 6 1 7 1 8 1 9 1 12 1 14 1 17 1 20 1 21 1 22 1 23 1 24 1 27 2 1 2 5 2 36 3 1 3 3 3 4 3 5 3 6 3 7 3 8 3 17 3 19 3 21 3 27 3 28 3 30 3 33 5 1 5 2 5 3 5 4 5 5 5 9 5 14...

Page 324: ...tions 1 2 1 6 1 21 2 9 2 10 2 29 2 32 2 33 2 37 4 1 4 4 4 5 4 6 5 10 8 9 Special Function 1 1 2 10 2 11 2 13 2 16 2 18 2 19 2 20 2 23 2 25 2 31 2 33 2 35 4 11 4 12 4 13 4 14 4 18 5 10 5 12 5 14 8 11 9...

Page 325: ...3 04 99 ALSPA GEM80 400 SERIES CONTROLLERS TECHNICAL MANUAL Index Page 5 Watchdogs 1 2 1 3 1 6 1 28 2 6 2 7 2 8 2 9 2 28 2 29 2 36 3 1 3 2 3 13 3 32 8 1 8 2 8 3 8 4 8 5 9 3 9 5 9 16 9 17 9 18 9 19 9 2...

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