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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: [email protected]

Summary of Contents for 4100

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: ...indication and control requirements The Gemini which you have purchased has the same high quality workmanship and advanced technological capabilities that have made Red Lion Controls the leader in today s industrial market Red Lion Controls has a complete line of industrial indication and control equipment and we look forward to being of service to you now and in the future CAUTION Risk of Danger ...

Page 3: ...I 20 A Codes 41 42 43 44 45 46 20 22 B Codes 51 52 53 54 55 56 22 25 C Codes 61 64 65 66 Preset Values Scale Factors A B Counter Load Values 25 27 E Dual Counter Batching Application 28 29 IV 20 MA CURRENT LOOP COMMUNICATIONS 30 A Communication Format 30 B Sending Commands Data To The Gemini 30 32 C Receiving Data From The Gemini 32 D Print Options 33 E Current Loop Installation 34 F Communication...

Page 4: ...her input provides the signal for a counter An anti coincidence add subtract mode is also provided to obtain a difference between two input signals Each channel features separate scaling and decimal point placement for readout in different units or at different resolutions A Counter Load feature enables the operator to modify the count value under circumstances that occur when flawed material has ...

Page 5: ...on the left side of the display show the function code the digits on the right side show the current programmed mode A mode selection is made by entering a new number On some of the entries you have the option of a plus or minus sign In the cases where a sign is required no sign will be displayed If you do enter a sign using the key a minus sign will be displayed in front of the appropriate digit ...

Page 6: ...ntered when the E key is pressed The Scale Factor Value will have a direct effect on the preset being entered if assigned to the counter For Scale Factors greater than one the preset value should be an integer multiple of the Scale Factor If it is not the Gemini will automatically adjust the preset value up or down to force it to be evenly divisible by the Scale Factor The Timed Output 1 or 2 Valu...

Page 7: ... powered down To access the Counter Load value for the desired counter first press the key if necessary so that the display is indicating the counter value which is to be changed Secondly press the E key and while holding it down press the key The Gemini will now display the displayed Counter Load value It will be zero unless the value had been changed since the unit was powered up To change the v...

Page 8: ...500 Preset 1 set to 500 2 001000 Preset 2 set to 1000 If 41 1 is changed to 41 2 then the factory settings are as shown Keys struck Display Description 4 1 41 1 Personality selected as COUNTER RATE 4 2 42 3 Reset Rate A Output s Counter B 4 3 43 1 Count with Inhibit 4 4 44 1 Single edge counting B 4 5 45 1 Counter B Scale multiplier of 1 0 4 6 46 1 Counter B leading zero blanking and no decimal po...

Page 9: ...and manual reset All functions can be interrogated 5 PRESET AND COUNTER LOAD PROGRAMMING AND RESET ENABLED The entire front panel is disabled with the exceptions of Preset and Counter Load programmability All functions can be interrogated 6 PRESET SCALE FACTOR AND COUNTER LOAD PROGRAMMING AND RESET ENABLED The entire front panel is disabled with the exceptions of Preset Scale Factor and Counter Lo...

Page 10: ...roximately 0 5 sec Rapidly pressing E during self test can speed up the sequence INPUT CIRCUITRY SET UP There are two independent input channels on the Gemini Various types of sensor outputs can be accommodated by appropriate DIP switch set up These include TTL or CMOS logic current sinking current sourcing or dry contact and more Channel 1 consists of a logic input and a separate low level magnet...

Page 11: ...nnel B functions as a counter See the PROGRAMMING INSTRUCTIONS FOR THE GEMINI 4000 section for details 41 2 DUAL COUNTER In this mode both display channels A B function as counters CODE 42 RESET BUTTON TERMINAL ACTUATION MODES The Reset Button Terminal Actuation Modes controls the affect that the reset button and terminal have on the two display channels Resetting will not affect the rate display ...

Page 12: ...ter operation which will prevent false counts from occurring due to back lash vibration chatter etc When two edge counting is used the quadrature mode works the same as with single edge counting when Input 2 is low But when Input 2 is at a high level counts at Input 1 are no longer ignored Instead the logic rules for Input 1 are complemented allowing both edges of Input 1 to be counted This double...

Page 13: ... which allows Preset 1 to track Preset 2 If Preset tracking is programmed whenever the Preset 2 value is changed the Preset 1 value will also change to maintain the same offset For example if Preset 1 is 100 and Preset 2 is 200 changing Preset 2 to 300 will automatically change Preset 1 to 200 maintaining same 100 unit offset In order to change the amount of offset the Preset 1 value is changed Th...

Page 14: ...set 1 Value Output 1 is activated If the display value were to drop below Preset 1 Output 1 would then deactivate For negative Preset points Output 1 is not activated when the count value is more positive than the Preset 1 Value When the count is more negative than only possible with counter or equal to Preset 1 Output 1 is activated If the count becomes more positive than the Preset 1 Value the o...

Page 15: ... display value count or rate is less than the Preset 2 Value Output 2 is not activated normal phase When the display value is greater than or equal to the Preset 2 Value Output 2 is activated If the display value were to drop below Preset 2 Output 2 would then deactivate For negative Preset points Output 2 is not activated when the count value is more positive than the Preset 2 Value When the coun...

Page 16: ...l to COMMON or if the front panel reset is enabled by pressing the front panel reset button Reset is maintained 56 2 MANUAL RESET TO PRESET RTP Manual reset to Preset is accomplished by pulling the RST terminal to COMMON or if the front panel reset is enabled by pressing the front panel reset button Reset is maintained 56 3 AUTOMATIC RESET TO ZERO AFTER TIMED OUTPUT The counter automatically reset...

Page 17: ...es not receive the next negative count edge within the maximum update time at the start of the measurement period the unit will end the time period and the rate display will go to zero At very slow count rates the update time period will be the actual period of one count cycle 63 1 0 5 Sec minimum 1 Sec maximum 63 2 1 Sec minimum 2 Secs maximum 63 3 2 Sec minimum 4 Secs maximum 63 4 4 Sec minimum ...

Page 18: ...uals the preset value when output is assigned to that display channel an output action will occur This action depends on the previously programmed modes The preset values may range from 999 999 to 999 999 Refer to Programming the Presets Scale Factors Timed Outputs Counter Load Values section for instructions on entering the preset values The Counter B Scale Factor SFB will have a direct effect on...

Page 19: ...ould cause the internal count value counter to be exceeded before the 6 digit display value is exceeded COUNTER LOAD VALUE The Counter Load Value is provided to allow the user to modify the count value The Counter Load Value is reset to zero when the Gemini is powered up Once the Counter Load Value has been changed it will remain set to that value until the unit is powered down and up Accessing th...

Page 20: ...require bi directional counting so the Gemini 4200 will be programmed for the Count with Inhibit Inputs 1 2 Response Mode In this mode both the rate indicator and counter will utilize the same input signal The switch settings and the wiring connections are as shown The Input 2 switch positions 5 7 are set to put the Input 2 in the non inhibit state with maximum noise immunity SCALING THE COUNTER I...

Page 21: ...imum speed Note The Timed Output 1 Value code 53 is not used in this application STEP 9 Enter code 54 Output 2 Termination Modes Select and enter mode 4 for Output 2 Terminate at Manual Reset Note The Timed Output 2 Value code 55 is not used in this application STEP 10 Enter code 56 Counter B Reset Modes Select and enter mode 1 for manual reset to zero STEP 11 Enter code 61 Rate Right Hand Dummy Z...

Page 22: ...ROGRAMMING INSTRUCTIONS FOR COUNTER RATE VERSION OF THE GEMINI section for details 41 2 DUAL COUNTER In this mode both display channels A B function as counters CODE 42 RESET BUTTON TERMINAL ACTUATION MODES The Reset Button Terminal Actuation modes control the affect that the reset button and terminal have on the two display channels There is a separate Rst A terminal which resets Counter A when a...

Page 23: ... In quadrature times 4 both Input 1 and Input 2 serve as the count or quadrature input depending on their state In one instance Input 1 will serve as the count input and Input 2 will serve as the quadrature input In another instance Input 1 will be the quadrature input and Input 2 will be the count input This enables each edge positive and negative going of both inputs 1 and 2 to be counted This r...

Page 24: ...SSIGNED TO COUNTER B Gemini 4200 Only 51 2 OUTPUT 1 2 ASSIGNED TO COUNTER B CODE 52 OUTPUT 1 TERMINATION MODES The Gemini has six Output Termination Modes which control the way Output 1 will terminate or reset In all modes Output 1 will terminate immediately when the counter to which it is assigned is manually reset Output 1 termination modes 1 2 are available only with a Gemini 4200 and when both...

Page 25: ...Gemini If a value of 0 is entered into the display and the E key is pressed the unit will not enter the 0 but will stay in the data entry mode If a new value is not entered it will time out and the unit will continue to use its previous setting CODE 54 OUTPUT 2 TERMINATION MODES The Gemini 4200 has six Output 2 Termination Modes which control the way Output 2 will terminate or reset In all modes O...

Page 26: ... COUNTER B RESET MODES The Gemini has six different Counter B reset modes Note For Gemini 4200 all reset to preset modes reset to preset 2 There are also two methods by which manual reset can act on the counter reset must be enabled see function code 66 and dip switch set up The first is a maintained reset action where the unit is held at reset for as long as the reset terminal or reset button is ...

Page 27: ...the unit resets when reset is activated and starts counting even though the terminal or reset button may still be active A sign in front of the mode identifier indicates momentary reset action the absence of the sign indicates maintained reset action The activation and de activation response time for reset is 10 msec 61 1 MANUAL RESET TO ZERO RTZ Manual reset to zero is accomplished by activating ...

Page 28: ...ble manual reset When the PGM DIS program disable terminal is connected to COMMON access to all functions is disabled except for those listed below which will remain enabled All of the function codes and parameters can be interrogated regardless of the Operator Accessible Functions mode selected A sign in front of the mode identifier will disable the front panel Reset button and the RST terminal N...

Page 29: ...ired displayed units This includes conversion from different units of measure i e feet to meters etc The Scale Factor Values may range from 5 9999 to 5 9999 Refer to Programming the Presets Scale Factors Timed Output Counter Load Values for entering instructions It is important to note that the precision of a counter application cannot be improved by using a Scale Factor greater than one To accomp...

Page 30: ...f pieces cut This is achieved by using the output cut pulse at O2 SNK as an input count pulse to Input 1 of the Gemini 4200 The Inputs 1 2 Response mode of the unit would be programmed to the Separate Inputs mode Then whenever a cut is made the Gemini would increment Counter A to provide a total count of pieces cut HARDWARE SET UP The application drawing shows how the hardware for this system is t...

Page 31: ...ounter B Decimal Point Lead Zero Blanking Select and enter mode 3 for a decimal point in the hundredths location STEP 7 Enter code 51 Output Assignment Select and enter mode 2 to assign both outputs to Counter B and enable preset tracking STEP 8 Enter code 52 Output 1 Termination Modes Select and enter mode 2 for termination at Output 2 end Note The Timed Output 1 Value code 53 is not used in this...

Page 32: ...UNICATION FORMAT Data is sent by switching off and on the current in the 20 mA current loop Data is received by monitoring the switching action and interpreting the codes that are transmitted In order for data to be interpreted correctly there must be identical 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 th...

Page 33: ...ansmit per Print Options P command does not require a Value Identifier 3 If the Change Value command is being used the next characters in the command string is the numerical data value 4 The last character in the command string is the command terminator This character must be sent in order to tell the Gemini that the command string is complete so that they can begin processing the command Below ar...

Page 34: ...terisk preceding the most significant digit of the value The decimal point position will float within the data field depending on the actual value it represents For peripheral control purposes a single line transmission will have a CR attached to the end of the above string For a T command or each line of a block transmission only the above character string is sent For the last line of a block tra...

Page 35: ...ble are A Print Display A count or rate value B Print Display B Count Value C Print Display A B Values D Print Preset 1 2 and Scale Factors A B E Print Display B Presets 1 2 and Scale Factors A B F Print Display A Presets 1 2 and Scale Factors A B G Print Display A B Presets 1 2 and Scale Factors A B A typical print out is shown below The Print Options are selected by setting S3 S4 and S5 on the S...

Page 36: ...re accessible through the side of the Gemini A list of the DIP switch positions and their functions are shown in the figure at right BR0 BR1 BAUD RATE Set up is shown at right When changing the Baud Rate the unit should be powered down and then powered back up again The unit will only recognize a baud rate change upon power up after activating the Print Request terminal or after a few characters h...

Page 37: ...THER GEMINIS OR RLC PRODUCTS WITH 20 MA CURRENT LOOP CAN BE CONNECTED IN THE SAME LOOP The drawing below shows the Current Loop set up Each Gemini is given an address and the Serial DIP switches are set accordingly A Baud Rate of 1200 is selected and set in each of the Geminis An application program is written which sends and retrieves data from the units using the Change and Transmit Value comman...

Page 38: ...te the transmissions from the Gemini 6 When sending commands to the Gemini the 2Ah must terminate the command NO CARRIAGE RETURNS 0Dh OR LINE FEED 0Ah CHARACTERS SHOULD BE SENT TO THE GEMINI If they are sent the Gemini will not respond to the next command 7 For applications where 1200 Baud or lower is used the command terminator can be sent before the string to eliminate any illegally transmitted ...

Page 39: ... 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 Consideration should be given to the thickness of the panel A panel which is too thin may distort and not provide a water...

Page 40: ...tective earth 2 Shielded screened cables for Signal and Control inputs with shield drain wire connected to earth ground at the mounting panel only Belden 84512conductor 22AWGtwistedpairwithfoilshieldanddrainwire Belden 8771 3 conductor 22 AWG with foil shield and drain wire Alpha 2404 4 conductor 22 AWG with foil shield and drain wire 3 Metal bezel of unit connected to mounting panel with 9 inch 2...

Page 41: ...trol relays transformers and other noisy components 5 In very electrically noisy environments the use of external EMI suppression devices such as ferrite suppression cores is effective Install them on Signal and 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 Install line filters on the powe...

Page 42: ... up Output Power DC OUT terminal provides a DC output for sensor power 12 VDC 25 The maximum sensor current is 100 mA This terminal number is model dependent Refer to the label on the unit for correct number RELAY WIRING To prolong contact life and suppress electrical noise interference due to the switching of inductive loads it is good installation practice to install a snubber across the contact...

Page 43: ...switch contacts are used to generate count input signals Since the LO FRQ mode also provides very high immunity against electrical noise pickup it is recommended that this mode also be used whenever possible with electronic sensor outputs The LO FRQ mode can be used with any type of sensor output provided count pulse widths never decrease below 5 msec and the count rate does not exceed 100 cps 3 V...

Page 44: ...CONNECTIONS CONFIGURATION SWITCH SET UPS FOR VARIOUS SENSOR OUTPUTS See Note 5 ...

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Page 47: ...pull down resistor for sensors with current sourcing outputs S3 HI FRQ Removes damping capacitor and allows operation up to the max count frequency Min count ON or OFF time 50 usec U D or INH 50 Duty Cycle all other Inputs A B Response Modes LO FRQ Connects damping capacitor for switch contact debounce Limits count speed to 100 cps max Min count pulse ON or OFF time 5 msec See Note 2 Page 42 S4 HI...

Page 48: ...aximumand input pulse widths to 5 msec minimum Lo Bias Input trigger levels VIL 1 5 V VIH 3 75 V Hi Bias Input trigger levels VIL 5 5 V VIH 7 5 V Note Bias levels given are 10 12 VDC They vary proportionally with sensor supply voltage at DC OUT terminal 6 MAGNETIC PICKUP INPUT Sensitivity 150 mV peak typical 12 VDC Hysteresis 100 mV Input impedance 26 5 KΩ 60 Hz Maximum Input Voltage 50 Vp 7 RATE ...

Page 49: ...cal equipment for measurement control and laboratory use Part 1 IP65 Enclosure rating Face only IEC 529 Type 4 Enclosure rating Face only UL50 ELECTROMAGNETIC COMPATIBILITY Immunity to EN 50082 2 Electrostatic discharge EN 61000 4 2 Level 2 4 Kv contact 1 Level 3 8 Kv air Electromagnetic RF fields EN 61000 4 3 Level 3 10 V m 80 MHz 1 GHz Fast transients burst EN 61000 4 4 Level 4 2 Kv I O Level 3 ...

Page 50: ...ON DISPLAY 1 Data error on power up 1a Press E key b Check all function codes E ON THE DISPLAY 1 Data error detected by processor 1a Press E or R button b Check all function codes c Check signal lines for possible noise sources NO RESPONSE TO FRONT PANEL 1 Panel disabled 1 Consult manual on Operator Accessible Functions modes UNIT DOES NOT COUNT 1 No input 1 Check sensors connections 2 Input selec...

Page 51: ...counting mode 4 Verify functions and modes 5 Scale factor incorrect 5 Change scale factor value UNIT WILL NOT RESET 1 Front panel reset disabled 1 Check rear panel DIP switch 2 Reset disabled 2 Check function code 42 or 66 DATA VALUES AND FUNCTIONS WILL 1 Front panel locked out 1 Consult manual on Operator Accessible NOT CHANGE OR NOT RECORDED Functions mode 66 2 Incorrect programming procedure E ...

Page 52: ...nput 1 Rate Input 2 Counter 5 Quadrature Input 1 Cnt Rate Input 2 Quadrature 6 Quadrature x4 Input 1 Cnt Quad Rate Input 2 Cnt Quad 44 COUNTER NUMBER OF COUNT EDGES Cannot be programmed in Quad x4 1 Single Edge Counting x1 Count on falling edge of count input 2 Double Edge Counting x2 Count on both edges of count input 45 COUNTER SCALE MULTIPLIER 1 1 2 0 1 3 0 01 4 0 001 46 CNTR DECIMAL POINT LEAD...

Page 53: ... at Manual Reset End 5 Terminate after Timed Output 1 6 Boundary 53 TIMED OUTPUT 1 VALUE Range 0 01 to 599 99 sec 54 GEMINI 4200 OUTPUT 2 TERMINATION MODES Normal Phase Output normally OFF turns ON at preset Reverse Phase Output normally ON turns OFF at preset 1 Terminate at Output 1 Start Only available when 51 2 2 Terminate at Output 1 End Only available when 51 2 3 Terminate at Manual Reset 4 T...

Page 54: ...at Zero 61 RATE RIGHT HAND DUMMY ZEROS 1 1 Dummy Zero 2 2 Dummy Zeros 3 3 Dummy Zeros 4 No Dummy Zeros 62 RATE CONVERSION FACTOR 1 Rate Per Second x1 2 Rate Per Minute x60 3 Rate Per Hour x3600 63 RATE MINIMUM UPDATE TIME 1 0 5 Sec minimum 1 Sec maximum 2 1 Sec minimum 2 Secs maximum 3 2 Secs minimum 4 Secs maximum 4 4 Secs minimum 8 Secs maximum 5 8 Secs minimum 16 Secs maximum Maximum rate 7500 ...

Page 55: ...ed Front panel reset can be independently disabled by using DIP switch Reset Button RST Terminal Disabled This mode has no affect on the RST A terminal which is always enabled 1 No Functions Enabled 2 Preset Programming Enabled 3 Scale Factor Programming Enabled 4 Preset Scale Factor Programming Enabled 5 Preset Counter Load Programming Enabled 6 Preset Scale Factor Counter Load Programming Enable...

Page 56: ...puts Input 1 Counter A Input 2 Counter B 5 Quadrature Input 1 Cnt A Cnt B Input 2 Quadrature 6 Quadrature x4 Input 1 Cnt Quad Input 2 Cnt Quad 44 COUNTER A B NUMBER OF COUNT EDGES Cannot be programmed in quadrature x4 1 Single Edge Counting x1 Count on falling edge of count input 2 Double Edge Counting x2 Count on both edges of count input 45 COUNTER B SCALE MULTIPLIER 1 1 2 0 1 3 0 01 4 0 001 46 ...

Page 57: ...rminate after Timed Output 6 Boundary Automatically selects code 61 1 if 51 1 53 TIMED OUTPUT 1 VALUE Range 0 01 to 599 99 sec 54 GEMINI 4200 OUTPUT 2 TERMINATION MODES Normal Phase Output normally OFF turns ON at preset Reverse Phase Output normally ON turns OFF at preset 1 Terminate at Output 1 Start Only available when 51 2 2 Terminate at Output 1 End Only available when 51 2 3 Terminate at Man...

Page 58: ...s reset as long as reset is activated Momentary Unit will reset and start counting again even if reset is still activated 1 Manual Reset to Zero Automatically selected when boundary mode is used 52 6 2 Manual Reset to Preset 1 3 Automatically Reset to Zero after Timed Output 1 4 Automatically Reset to Preset 1 after Timed Output 1 5 Automatically Reset to Zero at Preset 1 Counter resets as soon as...

Page 59: ...Terminal Disabled This mode has no affect on the RST A terminal which is always enabled 1 No Functions Enabled 2 Preset Programming Enabled 3 Scale Factor Programming Enabled 4 Preset Scale Factor Programming Enabled 5 Preset Counter Load Programming Enabled 6 Preset Scale Factor Cnter Load Programming Enabled 1 PRESET 1 Up to 999999 2 PRESET 2 Up to 999999 3 Display A COUNTER A SCALE FACTOR Up to...

Page 60: ...obtained by dividing the Display Units by the Number of Pulses as shown in Formula 1 below FORMULA 1 KT Display Units Number of Pulses WHERE DISPLAY UNITS The number of units revolutions feet 10ths of feet meters etc that would be acquired after the Number of Pulses has occurred NUMBER OF PULSES The Number of pulses required to achieve the number of Display Units For the preceding example the Tota...

Page 61: ...T using Formula 1 KT Display Units Number of Pulses Formula 1 KT 1 62 0 016129 STEP 2 In this application 62 pulses per gallon provides more than enough resolution so the Number of Count Edges is left set to the factory configured value of 1 With a NCE value of 1 the remaining amount of scaling necessary is still 0 016129 KR KT NCE Formula 2 KR 0 016129 1 0 016129 STEP 3 In order to provide maximu...

Page 62: ... and it is desired to indicate the shaft speed in revolutions the display units would be revolutions It is obvious that 48 pulses will occur in one revolution In order to convert the pulse units to revolutions it is necessary for the Gemini to multiply the number of pulses by a scaling factor to convert the pulse units to revolution units The Gemini has two programming codes that serve to scale pu...

Page 63: ...es for 2 feet of linear travel Since the desired display units are to be in tenths of feet it is necessary to convert 2 feet to tenths giving us 20 tenths display units The Total Scaling Factor KT is calculated by simply plugging in the two numbers into formula 1 KT Display Units Number of Pulses KT 20 60 0 333333 In order to get the maximum number of significant digits in the Scale Factor we use ...

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Page 72: ...0 No GEM41060 Yes GEM41160 GEM42 Gemini 4200 No GEM42060 Yes 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 APPENDIX I ORDERING INFORMATION ...

Page 73: ...and expenses arising out of subsequent sales of RLC products or products containing components manufactured by RLC and based upon personal injuries deaths property damage lost profits and other matters which Buyer its employees or sub contractors are or may be to any extent liable including without limitation penalties imposed by the Consumer Product Safety Act P L 92 573 and liability imposed upo...

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