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GEM80-500 Series Controller

Contents

(08/04)

GEM80-500 Technical Manual (T2025En)

Page ix

6.3

Storing a GEM

80-500 Controller before Installation ........................................................... 6-2

6.3.1

Environmental Conditions and Protection............................................................................ 6-2

6.3.2

Capacitor Reforming ......................................................................................................... 6-2

6.4

Site Requirements .............................................................................................................. 6-2

6.5

Methods of Mounting......................................................................................................... 6-2

6.6

Panel Mounting the Controller............................................................................................ 6-3

6.6.1

Direct Mounting (without using a Panel Mounting Kit) .......................................................... 6-3

6.6.2

Using a 8890-4900 Panel Mounting Kit............................................................................. 6-3

6.7

Mounting the Controller in a Subrack ................................................................................. 6-4

6.8

Installation of Optional Modules......................................................................................... 6-6

6.8.1

Introduction....................................................................................................................... 6-6

6.8.2

Protection of Equipment from Static Damage ...................................................................... 6-6

6.8.3

Setting I/O, Serial Communications and GEMCAN I/O Module Jumper Links....................... 6-6

6.8.4

Setting FIP Module Subscriber Address................................................................................ 6-8

6.8.5

Installation of Optional Modules......................................................................................... 6-9

6.8.6

Connection of the 15 V Cable Assembly Referenced 41Y8230/10 ....................................... 6-9

6.8.7

Installation of an Optional Ethernet Module ...................................................................... 6-10

6.9

Supply and Earth/Ground Connections............................................................................. 6-11

6.10

Watchdog Relay Connections........................................................................................... 6-13

6.11

Connections for I/O Modules 9713-4020 and 9713-4021 ............................................... 6-14

6.12

Connections for Serial Communications Module 9714-4020............................................. 6-14

6.13

Termination of Serial Links ............................................................................................... 6-15

6.13.1

Termination of Serial Link when using RS485 .................................................................... 6-15

6.13.2

Maximum Length of Serial Links ....................................................................................... 6-15

6.13.3

Cable ............................................................................................................................. 6-15

6.13.4

Connectors ..................................................................................................................... 6-15

6.13.5

Segregation .................................................................................................................... 6-15

6.14

Commissioning Guidance................................................................................................ 6-15

6.14.1

Preparation ..................................................................................................................... 6-15

6.14.2

Documents Required........................................................................................................ 6-16

6.14.3

Handling Precautions During Setting Up of Equipment ...................................................... 6-16

6.14.4

Radio Frequency Interference (RFI).................................................................................... 6-16

6.15

Use and Setting of the Mode Switch.................................................................................. 6-17

6.15.1

Mode Switch Position 0 - Normal (A) ................................................................................ 6-17

6.15.2

Mode Switch Position 1 - Normal (B)................................................................................. 6-17

6.15.3

Mode Switch Position 2 – HALT......................................................................................... 6-17

6.15.4

Mode Switch Position 3 – Clear Store New System............................................................. 6-17

6.15.5

Mode Switch Position 4 – Firmware Update (FUP).............................................................. 6-18

6.15.6

Mode Switch Positions 5, 6, 7, 8 and 9 - Reserved............................................................. 6-18

6.16

Overview of the Commissioning Procedure ....................................................................... 6-19

Maintenance and Fault Finding.......................................................................... 7-1

7.1

General Guidance for Maintenance ................................................................................... 7-1

7.2

Safety and Handling Information........................................................................................ 7-1

7.2.1

Earthing/Grounding .......................................................................................................... 7-1

7.2.2

High Voltages.................................................................................................................... 7-1

7.2.3

Power Down before Removing Modules or Connectors........................................................ 7-1

7.2.4

Power Down Safety Procedure ............................................................................................ 7-1

7.2.5

On-line Programming........................................................................................................ 7-1

7.2.6

Testing a GEM80 System ................................................................................................... 7-2

7.2.7

Watchdog and Safety Circuits............................................................................................. 7-2

7.2.8

System Status Indication..................................................................................................... 7-2

7.3

Spare Modules .................................................................................................................. 7-2

7.4

Cleaning and Visual Inspection .......................................................................................... 7-2

7.5

Batteries............................................................................................................................ 7-3

7.6

Use of LED and Display Indicators ...................................................................................... 7-3

7.6.1

Controller Front Panel Indications....................................................................................... 7-3

7.6.2

Alphanumeric Status Display .............................................................................................. 7-3

7.6.3

System Status Indication..................................................................................................... 7-5

Содержание GEM80-500 Series

Страница 1: ...GEM80 500 Series Controllers Technical Manual Publication No T2025En Issue 3 08 04 ABCD...

Страница 2: ......

Страница 3: ...GEM80 500 Series Controllers Technical Manual Publication No T2025En Issue 3 08 04...

Страница 4: ...ons Publication T2025En Issue 2 11 02 Addition of FIP Module Publication T2025En Issue 1 08 02 Initial Release Manufacturer ALSTOM Power Conversion Ltd West Avenue Kidsgrove Stoke on Trent Staffs ST7...

Страница 5: ...ncorporation in installations apparatus and machines The product must not be used as a single item safety system In applications where maloperation of the product could cause danger additional means m...

Страница 6: ...Safety GEM80 500 Series Controller GEM80 500 Technical Manual T2025En 08 04 Page iv This page intentionally left blank...

Страница 7: ...Maintenance and Fault Finding to be carried out The GEM80 500 Series Controller is designed for upgrading existing GEM80 Systems and for new applications and this publication includes guidance for car...

Страница 8: ...Scope GEM80 500 Series Controller GEM80 500 Technical Manual T2025En 08 04 Page vi This page intentionally left blank...

Страница 9: ...fication 2 4 3 Configuration of Optional Modules 3 1 3 1 Introduction 3 1 3 2 Configuration of Optional Modules in the controller 3 1 3 2 1 Configuration Rules 3 1 3 2 2 Configuration Recommendations...

Страница 10: ...ne Program Changes 5 3 5 2 9 Off line Program Debugging 5 4 5 2 10 Loading Programs 5 4 5 2 11 Programming the Controller 5 5 5 3 User Program 5 5 5 3 1 Introduction 5 5 5 3 2 GEM80 500 Controller Ins...

Страница 11: ...when using RS485 6 15 6 13 2 Maximum Length of Serial Links 6 15 6 13 3 Cable 6 15 6 13 4 Connectors 6 15 6 13 5 Segregation 6 15 6 14 Commissioning Guidance 6 15 6 14 1 Preparation 6 15 6 14 2 Docum...

Страница 12: ...o 999 7 18 7 14 F Table Usage 7 20 7 15 Serial Communications Diagnostics F Tables 7 21 7 15 1 Printer Port 7 21 7 15 2 ESP Tributary Port 7 21 7 15 3 ESP Control Port 7 22 7 16 Serial Communications...

Страница 13: ...fication and Address Configuration 3 8 Figure 3 6 Serial Ports Ports 1 to 4 Pinouts 3 10 Figure 3 7 9714 4020 Serial Port Identification and Configuration 3 11 Figure 3 8 9720 4020 GEMCAN I O Scanner...

Страница 14: ...10 I Table for an ESP Control Port using Flexible Data Tables 4 10 Table 5 1 Pin functions for Programmer Port Port 0 5 2 Table 5 2 GEM80 500 Controller Instruction Set 5 6 Table 5 3 GEM80 Instructio...

Страница 15: ...es a System Specification 2 5 which outlines the compatibility with the GEM80 range of products and details those system features particular to the GEM80 500 Controller 1 1 2 Compatibility with other...

Страница 16: ...nal Modules Handle Mode Selector Switch Status Display Watchdogs Healthy Indicators Ethernet Rx Tx LEDs Ethernet Active LED Battery Low LED Programming Rx Tx LEDs Front Accessible Connections Programm...

Страница 17: ...Basic I O and One Verification I O Ribbon Cables The Module has connection facilities for one Basic I O Ribbon Cable of 256 bits capacity and one Verification I O Ribbon Cable of 1024 Words capacity...

Страница 18: ...with the controller Refer to the T1653 GEM80 Series Controllers FIP Technical Manual for full details about use with the GEM80 500 Controller Network Subscriber Address BCD Switches see 6 8 4 9 Way D...

Страница 19: ...ng AGP Advanced GEM80 Programmer Peerless Communications Built in Web Server 1 3 6 9720 4020 GEMCAN I O Scanner Module Board Number LED Board Selector Jumper Link see 6 8 3 Firmware Update Mode Pushbu...

Страница 20: ...GEM80 controllers details for the specification configuration installation and operation of a FIP Module for use with a GEM80 400 500 Controller Note The FIP Module used with the GEM80 500 Controller...

Страница 21: ...nzene acid fumes sulphur dioxide hydrogen sulphide and nitrous oxide Notes 1 Additional protection should be provided to prevent dust ingress when the controller is used in high dust concentration loc...

Страница 22: ...nector Wire size for Supply Wiring 1 0 mm2 equivalent 18 AWG A C Supply Connector Cold Condition IEC Connector IEC 60320 1 C14 with an integral ON OFF switch and a protective fuse 3 15 A size 5 0 x 20...

Страница 23: ...ection on Outputs Limit to 20 of nominal rail voltage Note The total power consumption for the required controller configuration can be calculated from the above specification The remaining current ca...

Страница 24: ...Watchdog Real time clock Battery backed data tables real time clock and user program Programming Port Firmware easily upgradable by the user 100 event system log I O Interface with optional modules in...

Страница 25: ...4 4020 Each module has two serial ports The Controller can also be fitted with a TCP IP Ethernet Module 9716 4020 a FIP module 9715 4020 and upto two GEMCAN I O Scanner modules 9720 4020 This section...

Страница 26: ...to keep the modules with the greatest power requirements nearest to the power supply b to give maximum space for the 15 V power supply cable assembly referenced 41Y8230 10 to be fitted c to provide an...

Страница 27: ...ication 1st Module 9713 4020 X X X X 9 9 9 9 9 Basic 3 Verification 2nd Module 9713 4020 M X X X 9 9 9 9 9 Serial Comms Port 1 Port 2 1st Module 9714 4020 9 9 9 9 X 9 9 9 9 Serial Comms Port 3 Port 4...

Страница 28: ...be disabled by selecting P93 1 in which case the Verification Interface scans all 1040 words of I O Connection to the 9713 4020 Module is by two 26 way ribbon headers mounted on the front of the modu...

Страница 29: ...dresses A B 0 to 31 Connection to the 9713 4021 Module is by two 26 way ribbon headers mounted on the front of the module Figure 3 2 shows the Jumper Link setting required for this configuration and t...

Страница 30: ...Modules is by four 26 way ribbon headers two per module Figure 3 3 shows the Jumper Link setting required for this configuration and the addresses covered by each ribbon For installation of the 9713 4...

Страница 31: ...I O Figure 3 4 shows the Jumper Link setting required for this configuration and the addresses covered by each ribbon For installation of the 9713 4020 and 9713 4021 Modules see Section 6 TP1 9713 402...

Страница 32: ...er Manual for more details 3 7 FIP Module 9715 4020 The GEM80 500 Controller can have a single FIP module fitted giving a single logical port with media A and media B connections Refer to the T1653 GE...

Страница 33: ...idle frame 0 FFFF 0 gives default value 8000 8000 is normally used on SlowFIP networks 9080 is normally used on WorldFIP networks P96 Byte ordering 0 No byte swapping 1 Bytes of each complete word are...

Страница 34: ...Terminal d Programming Port The signalling rate for Ports 1 to 4 is user selectable between 110 and 19 200 bits per second These rates are set in the P tables Figure 3 7 shows identification of the s...

Страница 35: ...GEM80 500 Technical Manual T2025En Page 3 11 PORT 2 9714 4020 9714 4020 TP2 9714 4020 1st Module 1 2 3 PORT 1 PORT 3 PORT 4 2nd Module Identification TP2 9714 4020 2nd Module 1 2 3 Jumper Link Positi...

Страница 36: ...f all the data tables applicable to the GEM80 500 Controller The individual data tables are included at Section 5 The data tables used for Serial Communications are listed at Table 3 3 Table 3 3 Data...

Страница 37: ...rate in all controller operating states i e halted running normal input and test inputs Full details of each mode of operation are included in the GEM80 400 T1614 Technical Manual 3 8 4 Installation I...

Страница 38: ...anual for full details about use with the GEM80 500 Controller however please note the reserved P Table in Table 3 5 C A N A C C A N B D 9720 4020 C A N A C C A N B D 9720 4020 9720 4020 1st Module GE...

Страница 39: ...erved for GEM80 500 GEMCAN I O Scanner P Table Description Comment P73 Pointer to GEMCAN I O Scanner Module s Configuration Data e g 500 parameters start at P500 For installation of the 9720 4020 GEMC...

Страница 40: ...3 Configuration of Optional Modules GEM80 500 Series Controller GEM80 500 Technical Manual T2025En 08 04 Page 3 16 This page intentionally left blank...

Страница 41: ...80 Programming Tool section for details c Connecting the controller to a suitable GEM 80 Programming Package or a printer 4 2 Data Tables Refer to Table 5 5 for a list of all the data tables applicabl...

Страница 42: ...ail in the GEM80 400 T1614 Technical Manual which also includes details for the following topics a Communication Protocols e g Extended Simple Protocol ESP b Serial communications between two or more...

Страница 43: ...ted running normal input and test inputs 4 4 1 Direct Mode This mode is intended for use with a printer and a separate serial input device such as a matrix keyboard The port has two cyclic buffers one...

Страница 44: ...al Functions This is the only way to access these buffers from the GEM80 Ladder Diagram User Program However the input channel has a separate input line buffer in addition to the input cyclic buffer A...

Страница 45: ...an ETX 03 character or an end of line marker 0A is found The exception to this is if the program calls for output to commence while the operator is also keying in data on the keyboard In this case the...

Страница 46: ...re each GEM80 500 Controller Serial Port as an ESP tributary Table 4 4 shows the J K and I table data associated with ESP Tributaries Table 4 3 Configuring an ESP Tributary Port P table data Port 1 Po...

Страница 47: ...31 2 ESP Control Port Mode P12 P32 P112 P132 0 Free running Mode 1 User control Mode P13 P33 P113 P133 Bits 0 to 7 enable transmission to addresses 0 to 7 P14 P34 P114 P134 Number of tables to be tran...

Страница 48: ...flag tributary address 4 Bit 13 Receive flag tributary address 5 Bit 14 Receive flag tributary address 6 Bit 15 Receive flag tributary address 7 I1 I41 I81 I121 Tributary 0 Tx and Rx message length bi...

Страница 49: ...r of tables to transmit assign Route 3 Maximum Value 128 P18 P38 P118 P138 Number of tables to transmit assign Route 4 Maximum Value 128 P19 P39 P119 P139 Number of tables to transmit assign Route 5 M...

Страница 50: ...ag Route 2 Bit 3 Transmit flag Route 3 Bit 4 Transmit flag Route 4 Bit 5 Transmit flag Route 5 Bit 6 Transmit flag Route 6 Bit 7 Transmit flag Route 7 Bit 8 Receive flag Route 0 Bit 9 Receive flag Rou...

Страница 51: ...addresses bits 0 to 7 Tx 0 to 15 bits 8 to 15 Rx 0 to 14 I11 I51 I91 I131 Route 2 Tx and Rx addresses bits 0 to 7 Tx 0 to 15 bits 8 to 15 Rx 0 to 14 I12 I52 I92 I132 Route 3 Tx and Rx addresses bits 0...

Страница 52: ...m scans and the I table is also only examined between scans in user control mode If a message is received that is longer than the space allocated the message is truncated and a fault flag is set see S...

Страница 53: ...to several controllers at whatever signalling rate is selected by the user The signalling rate which will be satisfactory for the given distance between the controller and a GEM80 Programming Package...

Страница 54: ...the correct baud rate either 9 600 or 19 200 baud Wiring details for the Programming Connection Port are given at 5 2 6 5 2 6 Programming Port Port 0 Connections The Programming port connector is a 15...

Страница 55: ...a version of the program it continues to run this old program The errors are reported by text messages and can be displayed by a suitable GEM 80 Programming Package a detailed discussion of compilatio...

Страница 56: ...ks on the presence of both Basic and Verification I O are suspended f All Serial Link protocols function normally during TEST INPUTS mode 5 2 10 Loading Programs Before loading a program it is recomme...

Страница 57: ...ogrammed only downloading to a suitable GEM 80 Programming Package is allowed 5 3 User Program 5 3 1 Introduction The GEM800 500 Controller User Program uses the GEM80 Ladder Diagram programming and t...

Страница 58: ...l 1 Output OUT Outputs 16 bit word to a specified data table location 1 1 Time Delay DELAY Time range 100ms to 54 minutes 1 7 Counter COUNT Counter with a capacity of 32 767 resettable 1 12 1 Relay Re...

Страница 59: ...768 2 1 78 Checksum CHKSUM T9 Calculates the checksum of data table contents 2 1 See Note 10 Standard Deviation STDDEV T18 Calculate mean and standard deviation of a number of values 2 11 See Note 11...

Страница 60: ...in words QSHIFT T27 Shifts bits of words left or right 1 0 7 10 7 Binary Manipulation Rotate bits in words QROTATE T28 Rotates bits of words left or right 1 0 8 24 Compare COMPARE T0 Compares two inp...

Страница 61: ...o a group of adjacent data table locations 1 0 See Note 22 BCD input conversion BCDIN S1 Converts up to 4 decades of BCD to binary 1 0 36 BCD output conversion BCDOUT S2 Converts binary to up to 4 dec...

Страница 62: ...x Qty Array with array 75 5 x Qty Array with constant 2 63 3 x Qty 3 N 2 Number of transitions 4 115 10 x Qty Array with array 95 9 5 x Qty Array with constant 5 115 8 x Qty Array with array 95 8 x Q...

Страница 63: ...wishes to access and use any P table he must explicitly declare the highest table in the program so securing the address range Refer to the GEM80 400 T1614 Technical Manual for examples Some GEM80 Sp...

Страница 64: ...base e of a value FP Pi PI S77 Provides Pi in FP Exponential EXP S84 Raises e to a specified power ex FP Standard Deviation STDDEV T18 Mean Standard deviation calculation Power POWER T70 Raises a valu...

Страница 65: ...cations when the system is running in EPROM Function Flash Memory RAM Source for User Program YES NO Compiled User Program NO YES see Note 1 User Text Messages YES YES see Note 2 P Tables YES YES see...

Страница 66: ...e controller remains halted 3 S0 remains unchanged The controller cannot be run until S0 is set to 0 Switch to Flash EPROM i The EPROMS Successfully Programmed message is sent to the System Event Log...

Страница 67: ...owed by a number e g G41 points to the word 41 in the G table If for example we were to look at the content of data table address G1 it may be BIT NUMBER 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 ACTUAL V...

Страница 68: ...TUAL VALUE 1 0 1 0 1 1 0 0 0 0 1 1 0 1 0 1 which can be interpreted as BINARY 1 0 1 0 1 1 0 0 0 0 1 1 0 1 0 1 DECIMAL 21451 HEXADECIMAL AC35 Decimal As shown in the above example when converting from...

Страница 69: ...e or two bits of a word are used e g G104 1 the whole word G104 is reserved by the controller A GEM80 Programming Package cannot work with bit addresses above 999 15 This restriction means for example...

Страница 70: ...set YES YES C These tables store data RECEIVED by the GEMCAN I O Scaner module s 0 YES Except if R0 0 set YES YES D These tables store data derived by execution of the user program for TRANSMISSION by...

Страница 71: ...r text messages and storing text messages NO NO YES R These retained workspace tables are available for the user program to use for storing counter values sequencers and general data 1 NO NO YES Excep...

Страница 72: ...ff On Cleared to Zero by Clear Store Command MAINTAINER M Available for user programmed test Write access from programmer with key removed Accessible in data list mode only 0 YES YES YES EPROM S Avail...

Страница 73: ...tion of Verification I O tables e GEMCAN I O Scanner configuration where GEMCAN is fitted uses P73 f FIP configuration where FIP is fitted uses P94 to P96 Note The FIP Module used with the GEM80 500 C...

Страница 74: ...or Serial Port 2 See Section 3 P50 P58 Reserved P59 Offset of configuration data for GEMLAN T module within P Tables See relevant documentation for details T2011En P60 P72 Reserved P73 Offset of confi...

Страница 75: ...be used more than once in program Set ON if result in Error due to or 32767 limits E0 8 E0 9 1st Plug in E0 10 E0 11 2nd Plug in Buffer filling flags Port 1 Port 2 Port 3 Port 4 For use when a 9714 4...

Страница 76: ...Reserved F3 FIP Run Time Fault Flag F4 FIP Configuration Fault Information F5 to F9 Reserved F10 to F89 Serial link diagnostics See 7 15 F10 to F29 Serial link diagnostics for Serial Port 1 See 7 15...

Страница 77: ...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 controller is math...

Страница 78: ...ed in the P Tables The allocations depend upon the communications protocols in operation refer to Section 3 and are shown at Table 5 10 Table 5 10 J K Table Content Address Content Remarks J K0 to J K...

Страница 79: ...ler is powered up V63 Always 0 No off line support V64 Firmware issue This is copied from the firmware issue in the format A_ V65 to V66 Reserved for System Usage V67 to V71 Plug in Module Identifiers...

Страница 80: ...5 Programming GEM80 500 Series Controller GEM80 500 Technical Manual T2025En 08 04 Page 5 28 Note 1 at Table 5 11 V1 bit 8 is set just before compilation and reset when compilation is complete...

Страница 81: ...signment When the equipment arrives on site it should be carefully unpacked and inspected for any sign of damage Handling precautions for equipment containing Electrostatic Sensitive Devices ESD shoul...

Страница 82: ...delivery inspection Where equipment is unavoidably subjected to high humidity e g for short pre commissioning periods during installation in a humid location it is recommended that any enclosure into...

Страница 83: ...ntroller is mounted with four M5 screws of maximum length 10 mm through the panel from the rear into the tapped inserts in the controller rear face 6 6 2 Using a 8890 4900 Panel Mounting Kit If access...

Страница 84: ...unted in a safe and compatible manner In upgrade applications where the GEM80 500 Controller is to replace an earlier controller type the power supply should be removed and the GEM80 500 Controller fi...

Страница 85: ...tion and Commissioning 08 04 GEM80 500 Technical Manual T2025En Page 6 5 185 0 mm 155 0 mm GEM80 500 CONTROLLER 4 Holes 4 5 mm diameter Figure 6 2 Fixing Hole Dimensions for Panel Mounting of a Contro...

Страница 86: ...ules must be observed a Personnel handling the modules should NOT wear outer clothing which will generate a static charge e g synthetic materials like nylon cotton is preferable b All personnel handli...

Страница 87: ...ic 1 Verification 9713 4020 TP1 1 to 2 2nd Module Basic 3 Verification 9713 4020 TP2 2 to 3 1st Serial Communications Module Ports 1 2 9714 4020 TP2 1 to 2 2nd Serial Communications Module Ports 3 4 9...

Страница 88: ...The GEM80 500 Controller FIP network subscriber address is set using two BCD switches on the FIP Module 9715 4020 These switches are shown in Figure 6 5 The address is an 8 bit hexadecimal value SW2...

Страница 89: ...ion Bus socket ensuring that pins and sockets line up e Gently push the two connector halves together until the module sits flat on the four mounting pillars already fitted to the controller motherboa...

Страница 90: ...ave been fitted there will be one cable assembly surplus to requirements and it is recommended that this be retained as a spare Controller Motherboard 15 V Power Supply Connector 15 V Power Supply Cab...

Страница 91: ...s and spring washers to the four mounting pillars i Replace the upper side cover and power supply assembly j Ensure that all four earthing grounding screws are refitted and tightened k Refer to Commis...

Страница 92: ...th ground wires to screw terminals marked L N and E respectively For DC supply applications connect DC to terminal marked L and DC to terminal marked N d Fit the cable clamp to provide strain relief f...

Страница 93: ...e be used usually in conjunction with a follower relay to interrupt the plant supplies in the event of the controller being halted or tripped when a fault condition is detected The Watchdog Connector...

Страница 94: ...hdog Circuit 6 11 Connections for I O Modules 9713 4020 and 9713 4021 Connections from the I O modules to the Basic and Verification I O are made by 26 way ribbon connectors The length of ribbon cable...

Страница 95: ...e of 180nF km and a maximum resistance of 40 km A recommended cable type is BELDON 9729 6 13 4 Connectors The connectors on the controller and the Serial Communications Module type 9714 4020 are of th...

Страница 96: ...testing setting up operations on equipment containing printed circuit boards PCBs with Electrostatic Sensitive Devices ESDs a All test equipment must be grounded to a common earth point b The system...

Страница 97: ...gram if required 6 15 2 Mode Switch Position 1 Normal B When power is applied the controller returns to the state prior to power removal e g running from RAM running from Flash EPROM Halted etc If the...

Страница 98: ...F W and the firmware release i e A the controller will be halted The GEM80 500 Controller is then awaiting a Firmware upgrade from a PC connected to the Programming Port 6 15 6 Mode Switch Positions...

Страница 99: ...mmissioning is as follows a Check the hardwired safety circuits into which the watchdog operates b Check the power supply c Check the processor d Add the Basic I O inputs first then outputs e Add the...

Страница 100: ...6 Installation and Commissioning GEM80 500 Series Controller GEM80 500 Technical Manual T2025En 08 04 Page 6 20 This page intentionally left blank...

Страница 101: ...in the controller 7 2 3 Power Down before Removing Modules or Connectors To allow safe access the GEM 80 power and where applicable plant side power should be switched off before removing or making co...

Страница 102: ...se modules are listed at Table 1 1 If a spare controller is stored for future use be aware of its 10 year battery shelf life limitation If it is necessary to return any modules to ALSTOM for repair th...

Страница 103: ...d displays shown at Figure 7 1 Where a fault is evident a quick guide to the state of the system can be obtained from the front panel indications The LEDs and displays are a Alphanumeric Status Displa...

Страница 104: ...This should both reduce plant downtime and improve fault reporting Errors detected by the user program may be output to the display by writing a user supplied three digit decimal error code to F1 whi...

Страница 105: ...st TRun Run Test Inputs THlt Halted Test Inputs BATT Battery low warning BOOT System checks that main code is present and correct F W Controller is in Firmware update mode all GEM80 functions are susp...

Страница 106: ...vailable and these are detailed at 7 7 2 7 7 2 Monitoring and Test Facilities It is possible to monitor program execution while the GEM80 is running subject to observing the safety precautions detaile...

Страница 107: ...k command if applicable 104 Data table RAM full Data tables are greater than 32 000 words approximately Use of large table location reference possibly accidental Reduce number of data table references...

Страница 108: ...reference Error at instruction X rung Y Reference over limit Edit program 120 Value instr present not required Error near instr X rung Y Value instruction is present after Special Function which is no...

Страница 109: ...replace controller 137 Invalid object region The compiler is storing object code to an incorrect area of memory Power off on and retry If problem persists replace processor module 139 P table limit ex...

Страница 110: ...longer required by a program that has been modified This can create confusion in the case of the P table since they may be created simply by attempting to access them through a suitable GEM80 Program...

Страница 111: ...e and B table addresses have the same number e g A4 and B4 or where addresses have a number greater than the maximum imposed by the hardware 7 9 4 Programming Routine for Correction of Compilation Err...

Страница 112: ...VE CHANGED is displayed on power up and the controller goes into halt mode The user may however run the program if desired 7 10 System Status at Power Up 500 to 699 If during the power up self test cy...

Страница 113: ...ery changed 606 Unable to switch to RAM Failed to copy program to RAM when the S0 location was set to 0 The processor module is probably faulty and should be replaced 607 Unable to switch to EPROM Fai...

Страница 114: ...persists suspect the processor module 705 Processor local RAM failure Failed processor module Substitute spare processor module 706 FLASH checksum error Faulty data table source code Substitute spare...

Страница 115: ...ulty RAM on processor module Substitute spare processor module 733 Firmware checksum failure EPROMs have failed Substitute spare processor module 734 Battery failure and power removed when in a change...

Страница 116: ...elf test system operates as shown Execution a One full cycle of start up tests at power up b I O tests repeated every scan c Regular on line repetition of running tests Faults which immediately trip t...

Страница 117: ...Table 7 5 details the Interprocessor Communications Error Messages Table 7 5 Interprocessor Communications Error Messages Code Fault Message Possible Causes Recommended Recovery 806 IPC timeout to da...

Страница 118: ...m in region queue 908 Not in region when executing EXIT_PLC_REGION 909 Insufficient memory for organiser tables 910 Interrupt already defined 911 Insufficient memory for organiser tables 912 Insuffici...

Страница 119: ...0 interrupt 960 Single step error 961 INT0 interrupt 962 Escape Opcode error 963 Array bounds error 964 Invalid timer interrupt 965 FIP interrupt 966 Invalid key switch position 967 Invalid serial lin...

Страница 120: ...tem fault bits See below F2 0 Set to 1 if previous program cycle exceeds 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 sc...

Страница 121: ...able to the user program 7 15 Serial Communications Diagnostics F Tables Ports 1 to 4 are each allocated 20 F tables as follows Port 1 F10 to F29 Port 2 F30 to F49 Port 3 F50 to F69 Port 4 F70 to F89...

Страница 122: ...s truncated F10 11 F30 11 F50 11 F70 11 Last message on route 3 was truncated F10 12 F30 12 F50 12 F70 12 Last message on route 4 was truncated F10 13 F30 13 F50 13 F70 13 Last message on route 5 was...

Страница 123: ...s Ports 1 to 4 are each allocated 20 F tables as follows Port 1 F90 to F109 Port 2 F110 to F129 Port 3 F130 to F149 Port 4 F170 to F199 The first two statistics for each port are in two locations and...

Страница 124: ...F94 F114 F134 F154 Number of hardware errors Framing errors F95 F115 F135 F155 Number of time outs F96 F116 F136 F156 Number of CRC errors in received data F97 F117 F137 F157 Number of data errors Inc...

Страница 125: ...54 Number of hardware errors F95 F115 F135 F155 Number of time outs on receive F96 F116 F136 F156 Number of CRC errors in incoming message F97 F117 F137 F157 Number of NAK replies Short messages recei...

Страница 126: ...ntents are incremented after each successful compilation V1 8 1 Moving See note 1 V2 to V47 Used by system software for data table offsets and lengths V48 to V51 Reserved for system usage V52 Length o...

Страница 127: ...used to hold configuration data for serial links The reason for not clearing this section of P table is that GEM80 500 Controllers may be programmed either from the front port of the processor or rem...

Страница 128: ...ssages f system information messages g compilation error messages The contents of the System Event Log may be displayed saved to a file printed and cleared by issuing a simple command from a suitable...

Страница 129: ...the README TXT file supplied with the firmware update programme should be followed in order to complete a successful firmware update The firmware update mode is selected when the controller is powered...

Страница 130: ...ssible the original packing should be used 7 25 Disposal The GEM80 500 Controller should be disposed of in accordance with the laws of the country of use Modern high technology materials have been use...

Страница 131: ...be replaced by the GEM80 500 Controller This list may not be fully comprehensive If the user has a GEM80 system installed which is not listed in the table contact the ALSTOM Product Service Centre Cus...

Страница 132: ...pgraded contact the ALSTOM Product Service Centre Customer Support for advice see 7 24 for contact details There are some GEM80 systems which may require a new I O subrack when a GEM80 500 Controller...

Страница 133: ...be required also RS232 to 20mA conversion Table Declaration rung should be in existing ladder All Supported GEM80 142 These controllers had one or more concentrated I O expanders These could be repla...

Страница 134: ...instructions New I O Rack could be required 9714 4020 may be required also RS232 to 20mA conversion Table Declaration rung should be in existing ladder All Supported except Floating Point GEM80 165 T...

Страница 135: ...4020 may be required also RS232 to 20mA conversion Table Declaration rung should be in existing ladder All Supported GEM80 350 Series e g 351 352 353 These controllers could have paged video and or fa...

Страница 136: ...re has been fitted to a GEM80 system using 3xxx or 6xxx numbered code then functions may have been included which are not in the GEM80 500 Controller If this applies to the system to be upgraded conta...

Страница 137: ...tructions 24 V D C Power Supply Configured with option modules 8870C4979DC24 GEM80 500 Controller 20k User Instructions 48 V D C Power Supply 8870 4979DC48 GEM80 500 Controller 20k User Instructions 4...

Страница 138: ...9 Re Order Codes GEM80 500 Series Controller GEM80 500 Technical Manual T2025En 08 04 Page 9 2 This page intentionally left blank...

Страница 139: ...on Ltd France 9 rue Amp re 91345 Massy Cedex Tel 33 0 8 25 02 11 02 Fax 33 0 1 60 13 22 60 Germany Culemeyerstra e 1 D 12277 Berlin Tel 49 0 30 74 96 27 27 Fax 49 0 30 74 96 27 08 UK West Avenue Kidsg...

Страница 140: ......

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Alstom GEM80-500 Series, Техническое руководство

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