GEM33-J-cv.
GEM33-J-cv.QXD 11/10/2006 1:35 PM Page 2 INTRODUCTION The Gemini 3300 is another unit in our multi-purpose series of industrial control products that are field-programmable to solve multiple applications. This series known as the Astro-Line family of products, is built around the concept that the end user has the capability to program different personalities and functions into the unit in order to adapt to different indication and control requirements.
TABLE OF CONTENTS I. II. III. IV. V. VI. VII. VIII. IX. X. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming The Gemini 3300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displaying the Process, Batch & Total Count Values . . . . . . . . . . . . . . . . .
selected to automatically interrogate the Count Values, Presets, and Scale Factor by activating the “Print Request” terminal or by sending a “Transmit Per Print Option” (P) command. The relays are mounted on a plug-in board which makes it easy to field upgrade the Gemini 3300. The contacts are rated for 240 VAC or 28 VDC at 5 amps. The construction of the Gemini 3300 features a metal die-cast bezel, offering maximum durability with a high quality appearance.
Counter will display the number of batches that have been completed (up-count modes) or the number of batches left to complete (down-count modes). The Total Count is the total number of counts that have been received since the Total was last reset. It can be used to keep a running total of process units on a desired per shift, per day, per week, etc. basis. Like the Process and Batch Counts, the Total can be reset independently of the other two.
PROGRAMMING FUNCTION CODES Once the Scale Factor is displayed, changing the digits can be accomplished by repeatedly pressing the key beneath the digit position you wish to change or by holding the key down, allowing the digit to increment automatically. Entering function and mode is easily accomplished by pressing the appropriate digit key. To program the Scale Multiplier, you would enter 45 by pressing the front panel keys, 4 and 5.
It is possible to change the counter values of the Gemini 3300 by entering a “Counter Load Value”. This feature can be enabled or disabled by the programming of the “Operator Accessible Functions Modes”, function code 66. The “Counter Load Value” is stored when the unit is 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 that is to be changed.
FACTORY SETTINGS INITIAL FACTORY CONFIGURATION Keys Struck Display Description 4,3 4,4 4,5 4,6 5,2 5,3 5,4 5,5 6,1 6,2 6,3 6,4 6,5 6,6 43 1 44 1 45 1 46 1 52 5 0000.10 54 5 0000.10 61 4 62 1 63 1 64 3 0000.10 66 6 3 1 2 1 E & +/- 01.0000 000100 000200 000010 000000 Count with Inhibit Count on falling edge of Input A Scale Multiplier of 1.0 Leading zero blanking and no decimal point Output 1 terminates after Timed Output, Normal Phase Timed Output 1 Value of 0.
OPERATOR ACCESSIBLE FUNCTIONS WITH PROGRAMMING DISABLED DIAGNOSTICS, SELF TEST, & “WATCHDOG” TIMER The security of the Gemini 3300 is further enhanced by its self-test diagnostic and “watchdog” timer capabilities. The diagnostics are concerned with the special, no power memory of the Gemini 3300. When power is turned off, all pertinent function settings and measurements are automatically saved. When power is restored, the functions and data are re-instated.
INPUT CIRCUITRY & SET-UP There are two independent input channels on the Gemini 3300. 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 A consists of a logic input and a separate low level magnetic pickup input. Channel B is a completely independent count or control input channel.
PROGRAMMING INSTRUCTIONS FOR THE GEMINI 3300 BATCH COUNTER [43 3] TWO INPUT ANTI-COINCIDENCE ADD/SUBTRACT - This mode effectively separates count pulses which may simultaneously appear at the two inputs. The Gemini unit processes the count pulses into a string of time-separated pulses, so the internal counter will not lose any count pulses. Input A serves as the add input (count increments) and Input B serves as the subtract input (count decrements).
CODE 43 - INPUTS A & B RESPONSE MODES (Cont’d) CODE 46 - DECIMAL POINT & LEADING ZERO BLANKING CODE 44 - NUMBER OF COUNT EDGES [46 [46 [46 [46 [46 [46 1] 2] 3] 4] 5] 6] 0 0.0 0.0 0 0.0 0 0 0.0 0 0 0 0.0 0 0 0 0 LEADING ZERO BLANKING [46 [46 [46 [46 [46 [46 -1] -2] -3] -4] -5] -6] 000000 0 0 0 0 0.0 0 0 0 0.0 0 0 0 0.0 0 0 0 0.0 0 0 0 0.0 0 0 0 0 LEADING ZERO BLANKING INHIBITED [43 6] QUADRATURE TIMES 4 - This mode takes the quadrature mode, with two edge counting, one step further.
[52 1] TERMINATE AT OUTPUT 2 START - Output 1 (O1) will terminate when Output 2 starts. Output 1 is set for normal phase operation. [52 2] TERMINATE AT OUTPUT 2 END - Output 1 (O1) will terminate when Output 2 ends. Output 1 is set for normal phase operation. [52 3] TERMINATE AT MANUAL RESET - Output 1 (O1) activates when the Process Counter Value reaches the Preset 1 value. In this mode, once Output 1 is activated, it does not deactivate until the moment a manual reset occurs.
CODE 55 - TIMED OUTPUT 2 VALUE CODE 62 - PROCESS COUNTER RESET ACTION & PRESET TRACKING MODES The Gemini 3300 has the capability of varying the Timed Output 2 Value from 0.01 second to 599.99 seconds. When the code is entered, instead of a single mode identifier digit being displayed, six digits will be shown. Refer to “Programming the Presets, Scale Factor, Timed Outputs & Counter Load Values” section for more details about entering.
[62 4] AUTOMATIC RESET TO PRESET 2 AFTER TIMED OUTPUT 2 The Process Counter automatically resets to Preset 2 when Timed Output 2 ends. The “Output 2 Termination Mode” should be programmed for timed output operation, [54 5], when in this mode. Preset tracking is disabled. [62 5] AUTOMATIC RESET TO ZERO AT THE BEGINNING OF TIMED OUTPUT 2 (AT PRESET 2) - In this reset mode, the Process Counter will automatically reset to zero at the beginning of Timed Output 2 (at Preset 2).
CODE 64 - BATCH OUTPUT TERMINATION MODES (Cont’d) CODE 66 - “OPERATOR ACCESSIBLE FUNCTIONS” MODES A reverse phase mode is available on the Gemini 3300. This refers to the complementing of the logic state of the output. With normal phase operation, when the Batch counter value reaches the Batch Preset, the Batch Output will turn on. The reset condition of the Batch Output is output off. In reverse phase operation, the Batch Output turns off when the Batch Preset is reached.
display is reading in 10ths. In this case, the display will increment by two for each count input. Thus if an odd Preset Value was entered, such as 6.7 ft., the Gemini will alter the preset to read in even tenths of feet. Note: Use of a small Scale Factor in conjunction with a small scale multiplier could cause the internal count value (Process or Total Counter) to be exceeded before the 6-digit counter value is exceeded. PRESET VALUES The Gemini 3300 has three Preset values.
PROGRAMMING EXAMPLE This example depicts a typical application for the Gemini 3300. The programming steps and set-up will be discussed to give the user an understanding on how to configure the Gemini 3300. A typical industrial application for the Gemini 3300 will require a slow down output, a final stop output, and an end of batch output. The Gemini 3300 can be easily programmed to solve this requirement.
the motor control. A 12 VDC external relay (RLC # RLY10000) is used to deactivate the motor drive control and turn on the indicator light. DIP switch 1 is set to the logic position. This allows Input A to function as the count input. Switch position 2 is set to SNK. (current sinking), which provides an internal pull-up resistor to 12 VDC. Position 3 is set to HI FRQ. because of the high count speeds involved. Position 4 is set to HI BIAS for higher noise immunity.
STEP BY STEP PROGRAMMING OF THE GEMINI 3300 (Cont’d) STEP 8 - Enter Code 62 (Process Counter Reset Action Modes), and enter a 1 (Manual Reset to Zero with Preset Tracking enabled). STEP 9 - Enter Code 63 (Batch Counter Reset Action Modes), and enter a 2 (Manual Reset to Batch Preset). STEP 10 - Enter Code 64 (Batch Output Termination Modes), and enter a mode identifier of 3 (Terminate at Manual Reset).
GEMINI 3300 20 MA CURRENT LOOP COMMUNICATIONS The selection of the Baud Rate is done by setting DIP switches. Refer to the “Current Loop Installation” section, for set-up instructions. The Gemini 3300’s 20 mA Current Loop Communications Option allows a “two-way” serial communications link to be established in order to monitor or change the counter values, Presets and Scale Factor from a remote location.
2. The next character(s) in the command string is the actual command that the Gemini 3300 is to perform and the value identifier if it pertains to the command. (A command such as the Transmit per Print Options, “P”, command does not require a Value Identifier.) 3. If the change 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 (*).
A typical transmission, with the “PR.ID” (Print ID) switch in the up position, is shown below. The timing diagrams show the timing considerations that need to be made. FIG. 2: TIMING FOR SENDING COMMANDS (**) This is the time that it takes the Gemini 3300 to process the preset. It varies with the Count Rate and Scale Factor Value. The first two digits transmitted are the unit address followed by two blank spaces. If the unit address is 0, the first locations will be left blank.
PRINT OPTIONS CURRENT LOOP INSTALLATION The various Print Options are used mainly in conjunction with a printer and the Print Request Terminal. They provide a choice of Gemini 3300 data values to be printed when either the Print Request Terminal is activated or the “Transmit per Print Options” (P) command is sent to the Gemini 3300. The various Print Options available are: 1. 2. 3. 4. 5. 6. 7. 8. WIRING CONNECTIONS It is recommended that shielded (screened) cable be used for serial communications.
SERIAL DIP SWITCH SET-UP The Serial DIP switches are accessible through the side of the Gemini 3300. A list of the DIP switch positions and their functions are shown in Figure 4. BR0 & BR1, BAUD RATE - Set-up is shown in Figure 4, at right. When changing the Baud Rate, the unit should be powered-down and then powered back up again.
COMMUNICATIONS APPLICATION PROCESS MONITORING SYSTEM Five Gemini 3300s with 20 mA Current Loop Option, are used to monitor and control parts packaging machines in a plant. The units are located at each of the machines in the production area of the building. The communications lines are run to an Industrial computer located in the production offices. The drawing below shows the Current Loop set-up. Each Gemini 3300 is given an address and the Serial DIP switches are set accordingly.
TROUBLESHOOTING GEMINI SERIAL COMMUNICATIONS SERIAL LOOP-BACK SELF-TEST If problems are encountered when trying to get the Gemini(s) and host device or printer communicating, the following checklist can be used to help find the solution. The Gemini 3300 has a Serial Loop-back Self-test feature. This test enables the user to verify the operation of the Gemini when problems are encountered trying to get the Gemini and “Host device” communicating.
APPENDIX “A” - INSTALLATION & INPUT CONFIGURATION SWITCH SET-UP INSTALLATION ENVIRONMENT Before installing the Gemini 3300 into the panel, the user should first become familiar with the unit. It may also be desirable to program the unit and appropriate DIP switches for the application at hand (Refer to the “Programming and Applications” sections). Once the unit is programmed, the settings will be saved in memory. The Program Disable “PGM. DIS.” terminal should be connected to “COMM.
SHIELD TERMINATION EMC compliance installation testing had the drain wire for the shielded cable terminated as shown. The drain wire was less than 0.5" (12.7 mm) long. Select AC Power (115/230 VAC) The AC power to the unit must be selected for either 115 VAC or 230 VAC. The selector switch is located through an access slot on the side of the case (See figure on previous page or label on case). The unit is shipped from the factory with the switch in the 230 VAC position.
additional protection. Install line filters on the power input cable to the unit to suppress power line interference. Install them near the power entry point of the enclosure. The following EMI suppression devices (or equivalent) are recommended: Ferrite Suppression Cores for signal and control cables: Fair-Rite # 0443167251 (RLC #FCOR0000) TDK # ZCAT3035-1330A Steward #28B2029-0A0 Line Filters for input power cables: Schaffner # FN610-1/07 (RLC #LFIL0000) Schaffner # FN670-1.
AC POWER WIRING INPUT A & MAGNETIC PICKUP INPUT For best results, the A.C. power should be relatively “clean” and within the specified +/-10% variation limits. Drawing power from heavily loaded circuits or from circuits that also power loads that cycle on and off, should be avoided. The AC power is connected to the bottom left terminals TBA 1 & 2 marked AC PWR. The voltage selector switch, located at the side of the unit, is used to select the proper voltage.
INSTALLATION & REMOVAL OF THE RELAY BOARD NOTES: To install the relay board, locate the relay opening at the lower right-hand corner, on the back of the Gemini 3300. Pull the tab down while sliding the board into the two slots in the housing. The relay board will seat into the unit, allowing the tab to return to its original position. To remove the relay board, pull down on the tab just enough to allow the relay board to slide out. Grasp the terminal block and pull to remove the board. 1.
CONNECTIONS & CONFIGURATION SWITCH SET-UPS FOR VARIOUS SENSOR OUTPUTS (See Notes, Page 30) -31-
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SENSOR INPUT CONNECTIONS & INPUT CONFIGURATION SWITCH SET-UP CHAN. B CHANNEL A The accompanying diagram shows the details of Input A, Input B, and Magnetic Pickup circuit. The schematic circuit for Input B is almost identical to that of Input A, with the exception that Input B does not have the Magnetic Pickup circuitry paralleled with it. The four switches used to set up Input A and the Magnetic Pickup are designated S1, S2, S3, and S4. To set up Input B, use switches S5, S6, and S7.
APPENDIX “B” - SPECIFICATIONS & DIMENSIONS 1. DISPLAY: 6-digit 0.56" (14.2 mm) High LED display. 2. POWER REQUIREMENTS: AC Power: Switch Selectable 115/230 VAC , ±10%, 50/60 Hz, 20 VA DC Power: 11 to 14 VDC @ 0.7 amp maximum 3. SENSOR POWER: +12 VDC (±25%) @ 100 mA. 4. MEMORY: Non-volatile E 2 PROM memory retains all programming information, count values, and Counter Load Values when power is removed or interrupted. Power Cycles (ON/OFF): 100,000 minimum Data Retention: 10 yrs. minimum 5.
APPENDIX “B” - SPECIFICATIONS & DIMENSIONS (Cont’d) ELECTROMAGNETIC COMPATIBILITY: Immunity to EN 50082-2 Electrostatic discharge EN 61000-4-2 Level 2; 4 Kv contact1 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; 2 Kv power2 RF conducted interference EN 61000-4-6 Level 3; 10 V/rms 150 KHz - 80 MHz Power frequency magnetic fields EN 61000-4-8 Level 4; 30 A/m Emissions to EN 50081-2 RF interference EN 5501
APPENDIX “C” - TROUBLESHOOTING GUIDE Before applying power, double check all wiring. Improper AC voltage or AC connections may result in permanent damage to the unit. For further technical assistance, contact technical support at the appropriate company numbers listed. The majority of difficulties arising with the Gemini 3300 are related to incorrect hook-up and programming set-up. Always check all connections, function codes, Scale Factor, and Presets as a first step in troubleshooting.
APPENDIX “C” - TROUBLESHOOTING GUIDE (CONT’D) PROBLEM POSSIBLE CAUSE UNIT COUNTS INCORRECTLY 1. Input type incorrectly selected. REMEDIES 1. Check rear panel DIP switches. Turn on LO FRQ. switch for count speed of less than 100 cps. 2. Inputs incorrectly connected or loose connections. 2. Check sensors/input connections. 3. Check connections and wiring for noise sources. 3. Electrical interference. 4. Verify functions and modes. 4. Wrong “Inputs A & B Response Mode” 5. Change Scale Factor Value. 5.
APPENDIX “D” - GEMINI 3300 BATCH COUNTER MODE FUNCTION COMMAND CODE SUMMARY CODE 41 MODE DESCRIPTION LOAD FACTORY SETTINGS +/Batch Counter 43 INPUTS A & B RESPONSE MODES (counter only) 1 Count with Inhibit 2 Count with Up/Down Control 3 Add/Subtract 4 Anti-Coincidence Add/Add 5 Quadrature 6 Quadrature x4 44 NUMBER OF COUNT EDGES 1 Single Edge Counting (x) 1 2 Double Edge Counting (x2) 45 SCALE MULTIPLIER 1 1 2 0.1 3 0.01 4 0.
APPENDIX “D” - GEMINI 3300 BATCH COUNTER MODE FUNCTION COMMAND CODE SUMMARY CODE 52 53 54 MODE +/-1 +/-2 +/-3 +/-4 +/-5 NA +/-1 +/-2 +/-3 +/-4 +/-5 55 61 - DESCRIPTION OUTPUT 1 TERMINATION (+) Normal Phase (-) Reverse Phase* Terminate at Output 2 Start Terminate at Output 2 End Terminate at Manual Reset Terminate at Manual Reset End Terminate at Output 1 Time Delay TIMED OUTPUT 1 VALUE OUTPUT 2 TERMINATION MODES (+) Normal Phase (-) Reverse Phase* Terminate at Output 1 Start Terminate at Output 1 End Te
APPENDIX “D” - GEMINI 3300 BATCH COUNTER MODE FUNCTION COMMAND CODE SUMMARY CODE 62 MODE DESCRIPTION COMMENTS PROCESS COUNTER RESET ACTION & PRESET TRACKING MODES (+) Preset Tracking Disabled (-) Preset Tracking Enabled Preset 1 tracks Preset 2 +/-1 Manual Reset to Zero +/-2 Manual Reset to Preset +/-3 Auto Reset to Zero after Timed Output 2 +/-4 Auto Reset to Preset after Timed Output 2 +/-5 Auto Reset to Zero at Preset 2 +/-6 Auto Reset to Preset at Zero 63 BATCH COUNTER RESET ACTION MODES 1 Manual Rese
APPENDIX “D” - GEMINI 3300 BATCH COUNTER MODE FUNCTION COMMAND CODE SUMMARY CODE 66 MODE +/-1 +/-2 +/-3 +/-4 +/-5 +/-6 1 1 2 3 E & +/- Display P Display B Display P Disp P, B, T DESCRIPTION “OPERATOR ACCESSIBLE FUNCTIONS” MODES (+) Reset Button & “RST” Terminal Enabled (-) Reset Button & “RST” Terminal Disabled* No Functions Enabled Preset Programming Enabled Scale Factor Programming Enabled Preset & Scale Factor Programming Enabled Preset, 2-Button Reset & Counter Load Programming Enabled Preset, Scal
APPENDIX “E” - SCALING FOR COUNTING The Gemini 3300 is factory set to provide 1 count on the display for each pulse that is input to the unit. In many applications, there will not be a one to one correspondence between input pulses and display units. In these applications it will be necessary for the Gemini 3300 to scale or multiply the input pulses by a scaling factor to achieve the proper display units (feet, meters, gallons, widgets, etc.).
Scaling Factor, “K T ”, effectively becomes the Total Scaling Remaining, “KR”. (KR = 0.041667/1 = 0.041667) If the scaling remaining is between 0.6000 and 5.9999, it can be programmed directly into the Scale Factor value and the x1 factory setting for the Scale Multiplier, “SCM”, can be used. The general rule for choosing a SCM value is, when the Remaining Scaling Required, “KR”, is less than 0.6000, an SCM value of 0.1 or 0.01 can be used to get a Scale Factor value between 0.6 and 5.
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APPENDIX “G” - ORDERING INFORMATION MODEL NO. GEM33 DESCRIPTION w/20 mA Current Loop Gemini 3300 Gemini 3300 Relay Board No Yes PART NUMBERS FOR AVAILABLE SUPPLY VOLTAGES 115/230 VAC GEM33060 GEM33160 RLYBD002 For Information on Pricing, Enclosures, & Panel Mount Kits, refer to the RLC Catalog or contact your local RLC distributor.
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GEM33-J-cv.QXD 11/10/2006 1:35 PM Page 3 LIMITED WARRANTY The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to two years from the date of shipment, provided the products have been stored, handled, installed, and used under proper conditions. The Company’s liability under this limited warranty shall extend only to the repair or replacement of a defective product, at The Company’s option.
GEM33-J-cv.QXD 11/10/2006 1:35 PM Page 4 GEM33/IM-J 6/06 DRAWING NO.
