Gemstart 5

Gemstart 5
Volume 1 - Users
Guide
276192-111 Rev. G
Publication date : October 2011
Gemstart 5
Volume 1 Users Guide
Foreword
This Technical Handbook provides the User with the information necessary to Install,
Commission, Operate, Maintain and Test the equipment (as applicable). It is essential that
any Operator(s) reads and understands the content of this Technical Handbook and
follows the instructions contained within.
Every care has been taken to ensure the accuracy of the contents at the date of publication.
If the use of this equipment introduces new technology to your Operators, product training is
available from COMECA EBT to assist you in complying with relevant Health and Safety
Regulations.
Should you require further guidance or information regarding this equipment, or information
on our After Sales Services available, please contact our Customer Services Department at
the address below who will be pleased to assist:
COMECA Equipements Basse Tension
Route de Givry
ZI La Garenne
F71880 Chtenoy-le-Royal
France
Tel.:
+33 (0)3 85 98 22 00
Fax:
+33 (0)3 85 98 22 01
Web: www.gemstart.fr
Our policy is one of continuous product development.
equipment that may vary from that described.
We reserve the right to supply
The information contained within this Technical Handbook may not be reproduced or passed
on to third parties, either wholly or in part, without the express prior written consent of
COMECA EBT.
Gemstart5 declarations of conformity are available on the internet site or on demand.
-2-
Gemstart 5
Health and Safety

The User shall ensure that only qualified and authorised Operators, trained in the tasks to be
undertaken, are allowed to work on the equipment. All work must be performed in
accordance with local and national Health and Safety Regulations.
All relevant Warnings and Cautions shall be noted and their content strictly adhered to
during the Installation, Commissioning, Operation, Maintenance and Testing (where
applicable) of this equipment.
This equipment uses, or controls, fatal voltages. It is recommended therefore that Operators
working with, or near to, the equipment should be trained in resuscitation techniques.
The User has a duty of care to ensure that the equipment and/or its individual components
are disposed of in accordance with local and national Environmental Legislation and
Regulations. Some components may present a particular hazard to the environment if not
disposed of correctly.
The equipment must not be modified without prior consultation with COMECA EBT.
Modification without COMECAs consent may invalidate the warranty and any product
liability.
Should the Operator/User require any guidance or advice regarding the equipment, this can
be obtained by contacting COMECA EBT at the address below:
Route de Givry
ZI La Garenne
France
Tel.:
+33 (0)3 85 98 22 00
Fax:
+33 (0)3 85 98 22 01
-3-
Gemstart 5
Customer Services
COMECAs Customer Services Department can provide continuous Customer support
throughout the lifetime of your equipment. A comprehensive range of services is available,
including:
Installation and commissioning
Spare parts supply
Service and maintenance
Equipment repair
Refurbishment and modification
Engineering services
Training
COMECAs specialised Customer Service Engineers are available to provide the services
listed above, either in our workshop, or alternatively, at your site.
To assist us in providing an efficient and timely service, before contacting COMECA EBT to
discuss existing equipment, please help us by having the following information available:
The original COMECA EBT works order number or the unit serial number and the unit type
and voltage rating.
When you have the information listed above, please contact us at the address below:
Route de Givry
ZI La Garenne
France
Tel.:
+33 (0)3 85 98 22 00
Fax:
+33 (0)3 85 98 22 01
-4-
Gemstart 5
Table of Revisions
Issue
Description
Date
Original issue
May 2006
Added External Module Protection

A
Added 2
nd
Reset Input
July 2006
Updated Default table

Updated Default table
B
New RTD data Group 11
September
2006
Information about RTD on Network

Supply Ride-through extension
New profibus profiles
Updated new trending values (group 13)
Added default code on Profibus profiles with NTP tag
New basic schematic diagram
March 2007
Added PAMM wire color

Environment characteristics revision
Updated parts availability
Instructions for installation, use and maintenance
Profibus documentation information
Profibus profiles update
April 2008
Highlighted important points

Note on declaration of conformity
Corrected CT wiring table. In single phase application, power is
only calculated for CT1
Added information on Installation/Maintenance
Corrected Multi-voltage Input threshold voltage for 230VAC
Added ESD warning message on power connector page
January 2010
Added RTD Status Word to network

Change about Nowegian language
Corrected ANSI code
New logo
Added Auto-restart extended function (p34, 55)

Added current/power x100 multiplier (p55, 76)
-5-
September
2010
Gemstart 5
Information Gemstart5.3 end of life
G
Information ESD versions end of life

Modbus can be used in 4-wire option (p63, 64, 115)
New Data group 12 (individual currents) (p85)
-6-
October 2011
Gemstart 5
Acronyms and Abbreviations

Item
A
ac
ALC
CT
dc
FLC
I/O
kA
kV
LED
LCD
mA
mm
ms
MW
Ops
A
sec.
V
VT
Meaning
Amperes
Alternating Current
Actual Load Current
Current Transformer
Direct Current
Full Load Current
Input / Output
Kilo Ampere
Kilo Volt
Light Emitting Diode
Liquid Crystal Display
Milli Ampere
Milli Metre
Milli Second
Mega Watt
Operations
Micro Amperes
Second
Volt
Voltage Transformer
Symbols used within the Technical Handbook
ADVICE: information
intended to assist in
performing specified tasks
CAUTION: precautions to be
taken to avoid damaging the
equipment
YOUR ATTENTION IS
DRAWN: specific points
that should be noted
DANGER, ELECTRICITY:
precautions to be taken to avoid
injury to personnel
MECHANICAL DANGER:
precautions to be taken to
avoid injury to personnel
-7-
Gemstart 5
About this Guide

This guide provides basic information about Gemstart 5, introducing the user to its main
features, including the various hardware modules; the types of contactor control arrangements;
and the protection and control functions that can be used.
It also provides reference to the relevant items where the configuration of settings can be
carried out using the Configuration Editor Program; and refers to the basic control using the PC
Control Tool. There is also information on the communications links and protocols which can be
used to integrate Gemstarts into an intelligent control scheme.
Readership:
The Guide is intended for operating and maintenance staff and general engineers who are
responsible for monitoring Gemstarts system but do not necessarily have responsibility for
commissioning or reconfiguring Gemstarts settings.
Related publications:
Volume 2:
Gemstart 5 - Specification Reference Manual
Volume 2 is for use by expert engineers who will be setting up Gemstart systems.
Volume 3:
Gemstart 5 - GEMPRO - PC Control & Configuration Software Manual
Volume 3 is for the user and expert engineers, it explains the main features of the GEMPRO
software, including how to take control of your Gemstart; it also explains the features of the
Configuration Editor, including how the database structure works, and how it is used to enter
Gemstarts settings.
-8-
Gemstart 5
Table of Contents
1
INTRODUCTION ............................................................................................................................................ 12
MAIN FEATURES ........................................................................................................................................... 13
MAIN COMPONENT PARTS ........................................................................................................................ 14
HARDWARE DETAILS .................................................................................................................................. 15
4.1
BODY UNITS ................................................................................................................................................ 16
4.2
POWER SUPPLIES ....................................................................................................................................... 17
4.3
OPTIONAL EXTENSION MODULES ........................................................................................................ 17
4.4
INTERCONNECTIONS BETWEEN BODY UNITS AND EXTENSION MODULES .............................. 17
4.5
TYPICAL ARRANGEMENT OF GEMSTART INSTALLED IN A MCC CHASSIS ................................ 18
4.6
BASIC SCHEMATIC DIAGRAM ................................................................................................................ 19
4.7
CT WIRING ................................................................................................................................................... 20
PROTECTION AND CONTROL FUNCTIONS .......................................................................................... 21
5.1
CONTACTOR TYPE FUNCTIONS ............................................................................................................. 21
5.2
INPUT FUNCTIONS AND CONFIGURATION OPTIONS ........................................................................ 22
5.3
PROTECTION FUNCTIONS ........................................................................................................................ 24
6
6.1
6.2
6.3
INPUTS AND OUTPUTS ................................................................................................................................ 25

DIGITAL INPUTS ......................................................................................................................................... 25
6.1.1
Local inputs............................................................................................................................................ 25
6.1.2
Multi Voltage Field inputs ................................................................................................................... 25
6.1.3
Multi Voltage Interlock input ............................................................................................................... 26
6.1.4
Default mapping of Inputs...................................................................................................................... 26
DIGITAL OUTPUTS ..................................................................................................................................... 27

6.2.1
Hardware Outputs 1 to 4 Configuration Options .................................................................................. 28
6.2.2
Hardware Outputs 1 to 4 sense .............................................................................................................. 29
ANALOGUE INPUTS ................................................................................................................................... 29

6.3.1
Phase current inputs .............................................................................................................................. 29
6.3.2
FLC Setting ............................................................................................................................................ 30
6.3.3
ALC Setting ............................................................................................................................................ 30
6.3.4
Motor Starting Current .......................................................................................................................... 30
6.3.5
Contactor Rating .................................................................................................................................... 31
6.3.6
Thermal Overload Curves ...................................................................................................................... 31
6.3.7
Earth fault current input (CBCT)........................................................................................................... 34
6.3.8
Residual Earth Fault (5.4 only) ............................................................................................................. 34
6.3.9
Thermistor (PTC) input (Gemstart 5.4 only) ...................................................................................... 35
6.3.10 Motor supply monitoring ....................................................................................................................... 35

6.3.11 Auto - Restart ......................................................................................................................................... 36
-9-
Gemstart 5
6.3.12 Pt100 RTD inputs ................................................................................................................................... 38
7
DISPLAY MODULES...................................................................................................................................... 46
7.1
DISPLAY DATA CONFIGURATION. ........................................................................................................ 49
7.2
GEMSTART 5 FAULT MESSAGES ............................................................................................................ 50
7.3
GEMSTART FATAL ERRORS .................................................................................................................... 59
WATCHDOG FUNCTIONS ........................................................................................................................... 61
EVENT RECORDS .......................................................................................................................................... 62
9.1
MOTOR HISTORY ....................................................................................................................................... 62
9.2
EVENT HISTORY ........................................................................................................................................ 62
9.3
PLANT ASSOCIATED MEMORY MODULE (PAMM)............................................................................. 62
10
SYSTEM INTEGRATION .............................................................................................................................. 63
10.1
MODBUS INTERFACE ................................................................................................................................ 63

10.1.1 Configuration of the Serial Link ............................................................................................................ 64
10.1.2 Commands sent to Gemstart via the Serial Link .................................................................................... 65
10.1.3 Data available from Gemstart 5 ............................................................................................................ 67
10.1.4 Serial link timeout operation.................................................................................................................. 74
10.1.5 Serial link performance statistics ........................................................................................................... 74
10.1.6 Modbus Link Fault Indications .............................................................................................................. 74
10.1.7 Modbus Time Synchronisation ............................................................................................................... 75
10.2
PROFIBUS INTERFACE .............................................................................................................................. 75

10.2.1 Motor Management Starter .................................................................................................................... 76
10.2.2 Motor Management Starter Supported Profiles ..................................................................................... 78
10.2.3 Gemstart 5 Profile.................................................................................................................................. 78
10.2.4 Profile Data Structure Sizes ................................................................................................................... 80
10.2.5 Group Data ............................................................................................................................................ 81
10.3
GEMBUS INTERFACE ................................................................................................................................ 87

10.3.1 Configuration of the Serial Link ............................................................................................................ 87
10.3.2 Serial Link Commands ........................................................................................................................... 88
10.3.3 Data Available from Gemstart 5 ............................................................................................................ 90
10.3.4 Group Data ............................................................................................................................................ 92
10.3.5 Serial Link Timeout Operation .............................................................................................................. 92
10.3.6 Serial Link Performance Statistics ......................................................................................................... 93
10.3.7 Serial Link Compatibility ....................................................................................................................... 93
10.3.8 Serial Link Cabling ................................................................................................................................ 94
10.3.9 Termination of Serial Links.................................................................................................................... 94
10.4
GEMBUS 3 INTERFACE ............................................................................................................................. 95

10.4.1 Configuration for Gembus 3 .................................................................................................................. 95
10.4.2 Gembus 3 Commands ............................................................................................................................ 96
10.4.3 Data available from Gemstart 5 ............................................................................................................ 97
10.4.4 Gemstart 3 Fault Codes ......................................................................................................................... 97
- 10 -
Gemstart 5
10.4.5 Gemstart 3 Group Data ....................................................................................................................... 100
11
GEMSTART 5 ORDERING CODES ........................................................................................................... 104
12
GEMPRO PC SOFTWARE TOOL .............................................................................................................. 105
13
INSTRUCTIONS FOR INSTALLATION, USE AND MAINTENANCE ................................................ 106
14
GEMSTART PANEL CUTOUTS AND MOUNTING DETAILS ............................................................. 108
15
GEMSTART 5 CONNECTORS PIN OUTS ................................................................................................ 110
16
TECHNICAL SPECIFICATIONS ............................................................................................................... 113
16.1
GEMSTART 5 BODY UNITS .................................................................................................................... 113
16.2
EXTENSION UNITS ................................................................................................................................... 116
16.3
ENVIRONMENTAL ................................................................................................................................... 118

16.3.1 EMC ..................................................................................................................................................... 118
16.3.2 Mechanical........................................................................................................................................... 118
16.3.3 Climatic ................................................................................................................................................ 118
16.3.4 Fire and smoke..................................................................................................................................... 118
- 11 -
Gemstart 5
1 Introduction
Gemstart 5 is the next generation of the highly successful Gemstart family of intelligent
controller products brought to you by COMECA. It provides a completely new range of modular
units that enables the user to choose the level of complexity they require for their application.
This can range from a stand alone, single unit for status monitoring, to a fully extended control
and monitoring solution, integrated into a high level control system.
Its primary purpose it to control, protect and monitor important Medium and Low voltage
(MV/LV) loads used in process applications, such as motors, valves, and variable speed drive
units.
The Gemstart 5 can also be easily integrated into electrical distribution installations to monitor
and control various electrical supplies, including MV/LV feeders, circuit breakers and other
general purpose supplies.
It also has great flexibility in that you can incorporate Gemstart 5 units into a control scheme
with relative ease, as multiple devices may be connected on a single communications link with
options on three communications protocols: Modbus ; Profibus DPV1; and Gembus (proprietary
protocol);. All three come pre-loaded and are individually selectable.
- 12 -
Gemstart 5
2 Main Features
The main features provided by Gemstart 5 comprise:
Motor protection; for example protection against thermal overload, motor startup current and
earthing faults.
Application protection; for example protection against under current and instantaneous
overcurrent.
Process monitoring; to check for phase current imbalance.
Maintenance prediction; for example the hours run and the number of start/stop operations.
Motor control, for example startup duration time.
User interface; which for example provides fault descriptions and warnings information.
Electrical feeder control and monitoring; allows you to gather information on your load
profile, highest current, power etc, and allows you to control the load (turn it on or off) from a
remote position.
- 13 -
Gemstart 5
3 Main Component Parts

By selection of the appropriate hardware module(s) Gemstart 5 can provide the following
component parts:
Analogue inputs to monitor phase currents, phase voltage, thermistor inputs and earth faults.
Digital inputs to monitor plant status and local/remote push button controls.
Digital outputs to operate contactors and provide remote signalling.
A Liquid Crystal Display (LCD) to indicate status and mode.
Light Emitting Diodes (LEDs) to highlight status.
RS232 serial port for PC Control, Configuration of settings, and Software upgrades.
RS485 serial port for remote control and condition monitoring.
The component parts that are included are dependent on the type of module(s) selected. Details
of each module are listed under section 4.0 - Hardware Details.
- 14 -
Gemstart 5
4 Hardware Details
The hardware modules available on Gemstart 5 comprise the following:
Gemstart 5
Body unit
options :RS485 serial link
Version 5.1
Version 5.3 (end
of life)
Version 5.4
(optional extension
module)
(optional display
module)
4 x multi - voltage
inputs module
LED module
or
LCD module
or
4 x multi - voltage
inputs + 6 x
Thermistor inputs
module
RS232 PORT
8 way inter-connecting leads between units

Figure 1.0 Simplified overview of hardware
RJ45 sockets for

cable links between
units
Programming/
Configuration port
Primary
conduct
or
aperture
BODY UNIT
INPUT MODULE
- 15 -
LCD DISPLAY MODULE
Gemstart 5
4.1 Body Units

A body unit is required in every case where a Gemstart 5 is to be installed and comes in the
following versions, ascending in number with increasing functionality.
5.1 BODY UNIT
RS232 PROGRAMMING/CONFIGURATION PORT
RS485 SERIAL COMMUNICATIONS PORT
4 LOCAL 24V DC DIGITAL INPUTS
4 MULTI-VOLTAGE FIELD INPUTS (RANGE 24 110V DC & 24 - 240V AC)
1 MULTI-VOLTAGE INTERLOCK INPUT (RANGE 24 110V DC & 24 - 240V AC)
2 HIGH POWER RELAY OUTPUTS + 2 LOW POWER RELAY OUTPUTS
OPTIONAL PLANT ASSOCIATED MEMORY MODULE (PAMM)
5.3 BODY UNIT, AS 5.1 BUT WITH THE FOLLOWING ADDITIONS (end of life)
2 PHASE CURRENT INPUTS
1 CBCT INPUT FOR EARTH FAULT CURRENT MEASUREMENT
MOTOR VOLTAGE MEASUREMENT
AUTO RESTART FUNCTION
POWER PROTECTION
5.4 BODY UNIT, AS 5.3 BUT WITH THE FOLLOWING ADDITIONS/EXCEPTIONS:
3 PHASE CURRENT INPUTS
1 THERMISTOR / PT100 INPUT
Body unit options Table 1.0
- 16 -
Gemstart 5
4.2 Power Supplies

All body units have an option on two power supply ratings:
110 V 240V ac & 110V dc
24V 48V dc.
4.3 Optional Extension Modules

A range of extension modules are available to increase the functionality of your Gemstart
installation:
A - 4 x multi-voltage, digital field inputs (range 24 110V dc & 24 - 240V ac).
B - 4 x multi-voltage, digital fields inputs (range 24 110V dc & 24 240V ac) + 6 thermistor /
PT100 inputs.
C - LED module, includes 5 LEDs, 1 fixed green for unit healthy, 4 being tri-coloured and freely
assignable + a programming/configuration port.
D - LCD module, includes 5 LEDs , 1 fixed green for unit healthy, 4 being tri-coloured and
freely assignable + a 128 x 64 pixel back lit graphical liquid crystal display + a
programming/configuration port.
E - Chassis or cubicle mounted Plant Associated Memory Module (PAMM) retains
configuration settings, number of operations and trip/alarm log information.
4.4 Interconnections between body units and extension

modules
All optional extension modules, with the exception of the chassis or cubicle mounted PAMM,
which has a separate 3 wire connection to the body unit, are interfaced with the main body unit
using an 8 core inter-connecting cable fitted with an RJ45 plug on either end. This cable plugs
into a RJ45 socket on the body unit and on each module. This cable provides the power supply
from the body unit to the extension module(s) and includes the wires for data transfer between
each unit. The loss of communication with the extension module (IP or RTD) can be user
protected.
- 17 -
Gemstart 5
4.5 Typical arrangement of Gemstart installed in a MCC

chassis
LCD front panel on
chassis above
Contactor
with Aux.s
interface
wiring
MCCB &
Isolator
Main
conductors
Gemstart 5
Body Unit
inter-connecting
cable to front panel
- 18 -
Gemstart 5
4.6 Basic Schematic Diagram
NOTES:
The Earth Fault CT should not be earthed.
- 19 -
Gemstart 5
4.7 CT Wiring
When selecting which CT inputs to use there are some restrictions on which phases you can
use. The following tables show which built in CTs must be used.
The number of Motor Phases is configured in the GEMPRO Editor Supply form. The Number of
CTs used is configured in the GEMPRO Editor Phase CTs form.
Gemstart 5.3 (end of life)
Number of
Motor Phases
Number of CTs Used

1
Phase to Neutral
Use Phase 1 only
Not Valid
Not Valid
Phase to Phase
Use Phase 1 only
Not Valid
Not Valid
3 Phase
Not Valid
Use Phases 1 and 3
Not Valid
Phase 2 is residual sum

of phases 1 and 3
3 Phase
plus Neutral
Not Valid
Not Valid
Not Valid
Gemstart 5.4
Number of
Motor Phases
Number of CTs Used

1
Phase to Neutral
Use Phase 1 only
Not Valid
Not Valid
Phase to Phase
Use Phase 1 only
Use Phase 1 only
Not Valid
3 Phase
Not Valid
Use Phases 1 and 3
Use Phases 1, 2 and 3
Phase 2 is residual sum

of phases 1 and 3
3 Phase
plus Neutral
Not Valid
Not Valid
- 20 -
Use Phases 1, 2 and 3
Gemstart 5
5 Protection and Control Functions

The Gemstart 5 controller provides a large number of selectable protection and control functions
which you are able to activate from any of the input sources you have chosen to suit your
control application. These functions cover a wide array of contactor types for motor protection
and control, as well as controls for electrical distribution feeders.
In summary these functions cover:
Contactor type Functions
Input Functions
Protection Functions
Output Functions.
5.1 Contactor type functions

To define the type of control required from a Gemstart 5 unit it must be configured to the specific
contactor type using the Configuration Editor, under the Fuses and Contactors item. The
options available are as follows:
Contactor type
DOL-E
MCCB Feeder
VSD Logic
VSD Cut Throat
General Purpose I/O
Star Delta 1 O/P
Star Delta 2 O/P
Star Delta 3 O/P
DOL-L
Forward/Reverse
Motor Operated Valve
Two Speed - Low Start Only
Two Speed
Two Speed - Dahlander
A full description of each contactor function is detailed in Volume 2 Specification Reference

Manual.
- 21 -
Gemstart 5
5.2 Input Functions and Configuration Options

These are the functions that are available to be activated either by sensing the presence of volts
or the loss of volts at Gemstarts input terminals. (See Digital Inputs section 6.1). You can
assign any input number/type to any of these functions. You can also chose the logic type
sense you wish the function to have, e.g. N/O or N/C. It is also possible to configure the
severity of fault, that is issued when the input function is activated. All the following input
functions can be configured using the Configuration Editor, under items Fuses and Contactors,
Manual Controls and Digital inputs.
Input Function
Input Type Options
Fault Types
Configuration Options
Contactor
input
Contactor
input
Contactor
input
Contactor
input
Hard Stop
A auxiliary N/O, N/C
N/O, N/C
None, see contactor type

definition
definition
definition
definition
No Options, always a SCT
Process Stop A
N/O, N/C
Process Stop B
N/O, N/C
Manual Start A
N/O, N/C
No Options
Manual Start B
N/O, N/C
No Options
Emergency Start A
N/O, N/C
No Options
Emergency Start B
N/O, N/C
No Options
Test Mode Start
N/O, N/C
No Options
Manual Select
N/O, N/C
No Options, no fault is flagged
INCH Select
N/O, N/C
Remote Select
N/O, N/C
Interlock
N/O, N/C
OFF, SCW, LA, SCT, LT
Overload Relay
N/O, N/C
User text 1
N/O, N/C
User text 2
N/O, N/C
Thermistor Relay
N/O, N/C
ELCB Relay
N/O, N/C
Isolator
N/O, N/C
Device Status
N/O, N/C
Reset input 1
N/O, N/C
None
Reset input 2
N/O, N/C
None
Test Position
N/O, N/C
Counter 1
N/O, N/C
None
Counter 2
N/O, N/C
None
Counter 3
N/O, N/C
None
B auxiliary N/O, N/C

C auxiliary N/O, N/C
D auxiliary N/O, N/C
- 22 -
Gemstart 5
Note that if an input is set as N/C the function will become active if the input loses its voltage.
Conversely, with the input set as N/O, when the input detects sufficient voltage the function will
become active. The standard input type option is shown in bold.
Key to abbreviations
Abbreviation
Meaning
N/A
Not Applicable
N/O
Normally Open. Input function active when voltage level is present.
N/C
Normally Closed. Input function active when voltage level is lost.
LT
Latched trip. The trip flag must be cleared by a reset trips command.
SCT
Self Clearing Trip. If the trip input signal clears the trip flag is cleared
automatically
LA
Latched Alarm. The alarm flag must be cleared by a reset trips or reset
alarms command
SCW
Self Clearing Warn. If the warn input signal clears the warn flag is
cleared automatically
None
No faults are flagged when an input is defined as this
- 23 -
Gemstart 5
5.3 Protection Functions

This table lists all the Protection type functions that are available on Gemstart 5. They provide a
wide range of cover for most aspects of motor protection. All these protection functions are
selectable, together with additional configuration settings, using the Configuration Editor items
corresponding to the functions as listed in this table.
ANSI/IEEE No.
Protection Function
Configuration Editor item
79
Fail/Recovery Voltages
Supply
50S
Startup Current
Motor Protection
48, 51LR
Startup Time/locked rotor
Motor Protection
49
Thermal Overload
Thermal Protection
Thermal Reset Delay
Thermal Protection
Restart Inhibit
Thermal Protection
Temperature threshold
Thermal Protection
46
Single Phasing
Motor Protection
46
Imbalance
Motor Protection
66
Starts in Hour
Motor Protection
14
Speed sense
Digital Inputs & Motor Protection
27, 59
Voltage protection
Supply
50N, 51N
Earth Fault Protection
Earth Fault Protection
46
Phase Reversal
Supply
37
Under Current
Application Protection
50
Instant ALC
51
Constant ALC
Under Power
Power Protection
Over Power
Power Protection
55
Power Factor High
Power Protection
55
Power Factor Low
Power Protection
79
AutoRestart
Supply
74
Alarm Relay
86
Lockout
An explanation of the protection function and the settings parameters applicable to each of the
above can be found in volume 2 - Specification Reference.
NB: Current based protection is only applicable to Gemstart versions 5.3 & 5.4.
Voltage, Power and Auto-Restart protection is only applicable to Gemstart versions 5.3 & 5.4.
- 24 -
Gemstart 5
6 Inputs and Outputs

6.1 Digital inputs
6.1.1 Local inputs
There are four local digital inputs, numbered 1 to 4, available on all Gemstart body units. These
are powered from the internal 24V dc supply in the Gemstart 5 body unit. A common positive
24Volts is fed through the local chassis contacts and returned to the desired local input. They
are configurable to any of the input functions, but are typically used for contact position sensing.
e.g.
local/ remote switch position,
isolator opened/closed,
contactor opened/closed,
chassis test position.
It is only permissible for wiring associated with these inputs to be carried out locally within a
motor starter chassis or a feeder cubicle.
6.1.2 Multi Voltage Field inputs

There are four multi-voltage field inputs which are numbered 5 to 8 and are included in
Gemstart body units 5.1 to 5.4. They are rated in the range of 24 110V dc & 24 240V ac.
They are also configurable to any of the input functions, but are typically used for manual control
functions. e.g.
Field Start, Emergency Start
Field Stop, Hard Stop
Manual Select, Auto/Manual Select
The user must set the correct voltage rating for each of these inputs using the Configuration
Editor, under the Multi- voltage inputs item. The settings are either High Range (110/230v) or
Low Range (24/48v) The default is set to High Range. Please note that an input with low
volts applied will not become active if it has been set to sense the high voltage level.
In addition, a supply Ride Through Time setting of 0 to 200ms, in 10ms steps is also
configurable on these inputs. This is useful to prevent false input readings for momentary dips in
the input voltage. The default is set at 20ms. The switching on of the inputs is not delayed.
Warning! If input 8 is used for the Emergency Shut Down (ESD) option to control
output 4, the voltage applied to this input must be limited to 24V dc, otherwise the
output may be damaged.
Note : ESD version = end of life
A further four additional Multi voltage inputs, numbered 9 12, are available on both the
optional Input and the RTD/INPUT extension modules and these are connected to the body
units using the 8 way connection lead fitted with RJ45 plugs.
- 25 -
Gemstart 5
6.1.3 Multi Voltage Interlock input

This input has the same voltage rating as the multi voltage field inputs and must also be set to
the correct rating using the Configuration Editor. It is also freely assignable to any of the
Gemstart input functions, but it is usually reserved specifically for the Interlock function as the
default. The supply for this input is fed through the contacts of the two high power rated relays
located within the Gemstart body unit on versions 5.1, 5.3 & 5.4, and is typically used for direct
control of motor contactors. Therefore, the loss of this input will cause the contactors to drop
out.
The interlock input is monitored to detect the loss of the Interlock supply. e.g. When the input
opens this can be due to the operation of a Stop button or from the loss of the Interlock supply
source.
A configurable Ride Through Time of up to 200ms will allow the contactor(s) to be automatically
pulled back in if the interlock supply returns within this time setting. The default ride through time
is set to 200ms.
NB: A Stop signal of less than the Ride Through Time will be ignored by the Interlock input and
the contactor will be pulled back in as the Gemstart output will remain closed.
6.1.4 Default mapping of Inputs.

Across all the contactor types there is a common default setup for using the inputs. This is the
suggested use for each input, although Gemstart 5 allows you to use any input for any of the
input functions available.
Input Number/Type
Default input Function
Interlock (multi-voltage input)
Interlock. A self clearing TRIP (N/C Sense)
1 (24V local input)
Contactor A auxiliary contact (N/C Sense)
2 (24V local input)
Contactor B auxiliary contact (N/C Sense)
3 (24V local input)
Contactor C auxiliary contact (N/C Sense)
4 (24V local input)
Contactor D auxiliary contact (N/C Sense)
5* (multi-voltage input)
Process Stop A (N/C Sense)
6* (multi-voltage input)
Manual Start A (N/O Sense)
7*(multi-voltage input)
Not assigned
8*(multi-voltage input)
Manual Select (N/C Sense)
9**(multi-voltage input)
Not assigned
10** (multi-voltage input)
Not assigned
11* *(multi-voltage input)
Not assigned
12** (multi-voltage input)
Not assigned
Output 4
Not assigned
Table 3.0 Default mapping of inputs

Inputs 1 4 inclusive are available on all versions of Gemstart 5 body units.
* Inputs 5 8 inclusive are available on all body units.
** Inputs 9 12 inclusive are only available with the optional input extension modules.
- 26 -
Gemstart 5
Example:
Take the case of single contactor motors typical of direct on line starting; both Start A and Start
B functions can be used to start the motor. Start A could be for local control and Start B for
remote control. Assign Start A to input 6 and Start B to input 7.
It is also possible to set an output based on the level of an Input. This is available on a limited
number of inputs (Interlock, Local I/P 4, Multi-voltage I/P 7, and Extension module I/P 12). e.g.
For chassis test position, you could use the local input 4 to set output 3 to signal remotely that
the chassis is in test position.
Additionally, the status of output 4 can also be used to activate any input function.
A full description of all the input functions is detailed in Volume 2 Specification Reference
Manual.
6.2 Digital outputs

Gemstart versions 5.1, 5.3 & 5.4 include four digital outputs in the form of electro mechanical
relays that each have a pair of volt free, normally open, SPST contacts. Two of the relays are
high power rated (outputs 1&2) and are typically used to switch the supply to contactor coils for
motor control. These outputs are used for all contactor control configurations. The supply for
these outputs is fed from the Interlock input, so if the interlock supply is lost or isolated the
motor will stop.
Contact data high power relays

Configuration : 1 N/O contact
Type of contact : single contact
Rated current :12 A
Rated voltage / max. breaking voltage: AC 250 Vac /
Maximum breaking capacity : AC 4000 VA
Make current (max. 4 s at duty cycle 10%) 30 A
peak inrush current (20 ms) 80 A
Contact material AgSnO2
There are also two low power rated output relays (outputs 3&4) that are typically used for
remote status indication or additional contactor control when using the interlock supply.
Contact data low power relays

Configuration : 1 N/O contact
Type of contact : single contact
Rated current : 6 A
Rated voltage / max. breaking voltage : AC 250 Vac /
Maximum breaking capacity : AC 1500 VA
Make current (max. 4 s at duty cycle 10%) 15 A
Contact material AgCdO
- 27 -
Gemstart 5
Gemstart 5 also has an option to replace output 4 with an Emergency Shut Down (ESD) relay.
This option allows a 24VDC input signal from an ESD system to operate an embedded relay
within the Gemstart unit. Note : this version is declared end of life
All output contacts will drop out if the power supply to Gemstart is lost either momentarily or
permanently. However, see also sections 6.3.4 & 6.3.5 for details on Voltage Monitoring and
Auto-Restart features.
The output contacts will also drop out if the Gemstart 5 system watchdog detects a hardware or
fatal error software failure.
All relay contacts should be protected from large transient voltages caused by
switching external inductive loads. Either RC networks for AC voltage or Freewheeling diodes for DC voltage should be used in parallel with the external
loads.
6.2.1 Hardware Outputs 1 to 4 Configuration Options

The configuration options available to the hardware outputs 1 - 4 are defined below and can be
carried out using the Configuration Editor under item Fuses and Contactors.
Option
Description
Disabled
The output is Off all the time.
Active
The output source is On all the time.
Contactor Output A
This Function varies with contactor type but is generally the main
output drive
Contactor Output B
This Function varies with contactor type but is generally the

secondary output drive. If contactor B does not exist this output is
Off all the time.
Contactor Output C
This Function varies with contactor type. If contactor C does not

exist then this output defaults to the Trip Present status bit.
Contactor Output D
This Function varies with contactor type. If contactor D does not

exist then this output defaults to the No Trips Present status bit.
GP Output A
A GP Output bit supplied by the Host via the serial link. Used for
remote outputs
GP Output B
remote outputs
GP Output C
remote outputs
GP Output D
remote outputs
Motor Stopped
The contactors are open and there is no current flowing.
Running
One of the contactors is closed.
Running A
Contactor A is, or should be, closed.
Running B
Contactor B is, or should be, closed.
In Startup
Gemstart is in the startup phase.
Available to Auto
The motor is available for serial link commands. I.e. Gemstart is in

- 28 -
Gemstart 5
Option
Description
Auto or Priority Mode, there are no trips present, there are volts on
the interlock input and the contactor is not in the test position.
Any Fault Present
A Warn, Alarm, Trip or LTrip (Latched trip) is present. I.e. there is a

non zero fault code.
No Trips Present
There are no Trips or LTrips present.
Warn Present
There is a Warning present.
Alarm Present
There is an Alarm present.
Self
Clearing
Present
Trip There is a (self clearing) Trip present.
Latched Trip present
There is a (latching) LTrip present.
Available to Priority
A priority command can start the motor. I.e. there are no trips
present, the contactor is not in the test position, there are volts on
the interlock input and the Hard Stop input is not active.
Available to Manual
A manual command can start the motor. I.e. Gemstart is in Manual

Mode, there are no trips present, the contactor is not in the test
position, there are volts on the interlock input and the Hard Stop
and Process Stop inputs are not active.
Interlock Input
If this input is active it will act directly upon any one of the outputs it
has been assigned to.
Inputs 4, 7 or 12
If any one of these inputs is active it will act directly upon any one
of the outputs it has been assigned to.
6.2.2 Hardware Outputs 1 to 4 sense

The sense of the output signal Normally open or Normally closed is configurable. The default
is Normally Open. Selecting Normally Closed will invert the sense of the status bit. e.g. a N/C
sense will cause the output contact to open when the output function is active, and conversely,
a N/O sense will close the output contact when the output function is active.
Please note that when the unit is not powered these output relays will be open
regardless of configuration.
6.3 Analogue inputs

6.3.1 Phase current inputs
Gemstart unit version 5.3 has 2 phase current inputs (end of life).
Gemstart unit version 5.4 has 3 phase current inputs.
Phase current measurement is provided for motors/feeders in the range of 0.5 to 30 amps
nominal, using CTs integral to the body unit. The phase conductors are routed through the
apertures in the body unit to provide the primary winding for the integral CT.
Higher current ratings in the range of 30 to 1000 amps nominal are catered for using external
interposing CTs mounted in the motor chassis or feeder cubicle. These interposing CTs can
have either 1 amp or 5 amp secondaries with the secondary windings, likewise being routing
- 29 -
Gemstart 5
through the appropriate apertures in the Gemstart body unit.
The Gemstart body unit with the integral CTs has a current measuring error limit of 2%
across the nominal range of 0.5 30 amps, and within 5% across the range of 31 250
amps.
All external interposing phase CTs specified by COMECA comply with Class 5P10 Protection
category of IEC 60044-1, thereby providing exceptional total accuracy for all current
measurements.
Phase CT selection :
CT1 = INTEGRAL CT (NOT OPTIONAL)
EXTENDED NOMINAL CURRENT RANGE 0.5A 30A = INTEGRAL CT
CT2 = (100/1A)
EXTENDED NOMINAL CURRENT RANGE 25A 160A = CHASSIS

MOUNTED INTERPOSING 3CT BLOCK WITH 3 CTS FITTED.
CT2a = (100/1A)
(end of life)
EXTENDED NOMINAL CURRENT RANGE 25A 160A = CHASSIS

MOUNTED INTERPOSING 3CT BLOCK WITH 2 CTS FITTED.
Phase CT table 4.0
6.3.2 FLC Setting

Phase current settings are applied to the load to be protected based on the motor/feeder full
load current (FLC) and this is set up as follows using the Configuration Editor in the GEMPRO
PC program:
First select the Gemstart unit type, i.e. 5.1, 5.3, etc, then select Phase CTs item and finally
select the CT input type, e.g. Primary, 1 amp or 5 amp. Primary refers to the integral CT for use
up to 30 amps, whereas 1 amp and 5 amp refers to the secondary winding current rating of the
external interposing CTs. Then select the number of CTs.
Now close the Phase CT item and then select the Motor item to configure the FLC range and
the actual FLC value.
e.g. Using a Gemstart 5.3 on a motor with an FLC of 16 amps, the Primary CT would be
selected first, followed by the number of CTs as 2, then the FLC range entered as 10-100A,
then the FLC value entered as 16 amps.
For FLC values which result in a current of less than 0.5Amp through the integral CT, the
multiple turns option must be used. e.g. Using an interposing CT with a 100/1Amp ratio, this
limits the low current measurement range to 50Amps using 1 turn through Gemstart. However,
using multiple turns would allow Gemstart to measure lower currents with the same CT. For
example, 25Amps would require 2 turns and 10Amps would require 5 turns. The maximum
number of turns that can be passed through Gemstart comfortably using 1.0 mm PVC covered,
switchgear type cable is 5.
6.3.3 ALC Setting

The ALC (Actual Load Current) setting is set in a similar manner, but under the Application
item of the Configuration Editor. However, this may be left the same as the FLC setting as this is
its default setting.
6.3.4 Motor Starting Current

Motor starting currents can be set under the Motor item in the range of 100% 1000% of the
FLC, noting that this may be limited by the maximum current rating of the CT. The integral CT is
- 30 -
Gemstart 5
limited to a maximum current of 250Amps for 30 seconds, and all Gemstart specified
interposing CTs are limited to10x their nominal primary current rating for 30 seconds. The
standard default starting current setting is 800%.
6.3.5 Contactor Rating

Set to protect the contactor under heavy fault condition, allowing upstream fuse / MCCB
protection to operate first. Gemstart will keep the contactor closed for currents greater than this
setting value until the fuse blow time has elapsed. The default settings are 1000% of the FLC
value for the contactor rating and 1s for the fuse blow time. These may be changed under the
Fuses and Contactors item.
6.3.6 Thermal Overload Curves

Up to 31 Gemstart overload curves are available to choose from for the thermal protection of
your motor. They are typically selected based on the It withstand of the motor. This is usually
obtained from the maximum stall current and its withstand time from cold. You would typically
select a curve that would cause the overload protection to trip if these time/current parameters
were exceeded. Selection can be made under the Thermal item in the Configuration Editor.
Thermal overload protection is ATEX certified (Certification available on the internet site or on
demand).
- 31 -
Gemstart 5
Gemstart Curves
Curve 31
Gemstart Curves
Curve 30
Curve 29
Curve 28
100000
Curve 27
Curve 26
Curve 25
Curve 24
10000
Curve 23
Curve 22
Curve 21
Curve 20
1000
Curve 19
Curve 18
Curve 17
Curve 16
100
Curve 15
Curve 14
Curve 13
Curve 12
10
Curve 11
Curve 10
Curve 9
Curve 8
Curve 7
Curve 6
Curve 5
0.1
Curve 4
Fault Level (xFLC)
10
11
Curve 3
Curve 2
Curve 1
- 32 -
Gemstart 5
6.3.7 Earth fault current input (CBCT)

The earth fault current input is available on Gemstart 5.3 & 5.4.
Selected by setting Earth Fault Method to EF Input within the Earth Fault
configuration page of GEMPRO
Earth fault current measurement/protection can be provided when the three phase
conductors are routed through a core balanced current transformer (CBCT). Any
residual current is picked up by the secondary winding which is fed to an analogue
input within the Gemstart body unit where it is measured and compared to the earth
fault trip threshold setting.
Gemstarts earth fault input is nominally rated at 20mA and has a maximum
measurement limit of 120mA. The burden for the CBCT is 38. Various proprietary
CBCTs may be used but this upper limit of 120 mA must be borne in mind. The
CBCT wiring should not be earthed.
Tested types include Socomec W2-S70 (EF CT rating = 12A) and Socomec W4S140 (EF CT Rating = 12A)
You can set the Earth Fault level in the Configuration Editor. The 20mA nominal
rating of the input is assumed in the configuration.
E.g. for a 800 turn CBCT as below, the primary rating would be 800 x 20mA = 16A.
Therefore, set the CT primary rating Range = 10 -100A and the Earth fault CT
primary rating Value = 16 A.
You can then set the Earth Fault Trip Current to the desired value.
If the earth fault trip setting is selected above the input limit a Config Error fault
message will be reported on the LCD display.
The overall accuracy for earth fault current measurement is 2% for the Gemstart
input, plus the error contributed by the CBCT that is used. Please be sure that the
CBCT chosen has sufficient dynamic range to ensure an accurate result.
Gemstart specified CBCT:
CBCT (16/0.02A) CLASS 10P10
EARTH
FAULT
CURRENT
DETECTION
RANGE 1.0A 96A
CBCT table 5.0
6.3.8 Residual Earth Fault (5.4 only)

Residual earth fault is available on Gemstart 5.4
Residual Earth Fault is selected by setting Earth Fault Method to Residual CT within
the Earth Fault configuration page of GEMPRO.
Gemstart 5.4 uses 3 Current transformers to measure the individual phase currents.
If these three currents are summed together the resultant value is equivalent to the
earth fault current flowing. This value is then treated in the same way as the Earth
Fault Current Input (CBCT).
This method is inherently less accurate than the CBCT method as the current
reading is dependant on the individual phase CTs. This gives a larger scope for
introducing errors, particularly when using interposing CTs for large current motors
(>30A) or MV motors. Care should be taken to ensure that these interposing CTs are
matched or that any errors introduced by such CTs are accounted for.
- 34 -
Gemstart 5
Earth Fault setting below 10% of the FLC rating should not use this method.
The overall accuracy using this method of Earth Fault detection is +/- 5% in range 0.1
- 30A.
EF Limit must be between 10% and 100% of FLC. This accuracy does not include
any additional errors introduced by external CTs.
6.3.9 Thermistor (PTC) input (Gemstart 5.4 only)

Gemstart 5.4 has a built in positive temperature coefficient (PTC) input. This input
uses a standard PTC thermistor to detect an over temperature condition within the
motor.
Typically a PTC will have a low temperature resistance of up to 150 ohms at a
temperature defined by the supplier the PTC will experience a sudden change in
resistance resulting in values of over 10K ohms.
The Gemstart 5.4 unit measures these values and provides a fault condition if there
is an increase in resistance.
To allow up to three of these devices to be placed in series the following thresholds
are used
Trip at 1600 to 2000

Reset at 1000 to 1400
Gemstart can be configured to perform a LTRIP, TRIP, ALARM or WARN should the
threshold be exceeded
This protection is available in addition to the overload protection and is ideal for use
on motors that are in a raised ambient temperature or within a hazardous
environment.
6.3.10
Motor supply monitoring
On Gemstart versions 5.3 & 5.4 the body unit incorporates a voltage transformer
which is used to directly measure the motor supply voltage up to a maximum of 240V
ac. Higher voltage monitoring is possible by using an external interposing, step down
transformer. The motor supply can be monitored to detect motor supply loss or dips
down to 10 ms. The Monitored Voltage level, which must be set to the correct value
under the Supply item in the Configuration Editor, is used for both the Auto-Restart
feature and the Under/Over Voltage protection. The under voltage level is set by the
value selected from the Supply Fail level in the Auto-Restart feature and the Over
voltage level is pre-set at 110% of the monitored voltage value. The severity of the
fault issued for voltage protection is also selectable from the configuration settings.
Gemstart versions 5.3 & 5.4 can be powered independently to the motor supply,
however if the control supply is derived from the same source as the motor voltage
then this can be linked across to the motor supply input terminals to monitor this
source.
- 35 -
Gemstart 5
6.3.11
Auto - Restart
When motor supply monitoring is included, as it is in Gemstart versions 5.3 & 5.4, the
Auto-Restart feature is available to carry out automatic re-starting of the motor upon
restoration of supply. The re-start is carried out either immediately or after a set time
delayed period.
The Auto-Restart feature has five settings to be entered using the Supply item under
the Configuration Editor:
1. Supply Fail and Recovery voltage levels entered as percentages of the
monitored voltage value.
2. Ride through will ride through a motor supply failure of up to 5s. This will enable
an immediate auto-restart of the motor should the motor supply return within this time
period.
3. Maximum Dip Time will sense if the monitored voltage has returned within this set
time period. Auto-restart is aborted if the supply does not return within the Maximum
Dip Time period.
4. Delay to Restart is the next timing phase, following a return of the supply within
the Maximum Dip Time, before an Auto-restart is initiated.
See also fig 2 below for further explanation of the Auto-Restart feature.
Note that the Auto-Restart feature can be disabled if the Maximum Dip Time is set to
OFF.
5. Inputs Supply Volatile allows Gemstart5 to know if Multi-Voltage inputs are wired
on the busbar or backup. In the first case, Gemstart5 knows that it has not to read
the opening of Normally Closed inputs during a voltage dip and go on autorestart.
Warning : a system with volatile Multi-Voltage inputs (that lose supply during a
supply dip) cannot be used with Supply Ride-Through set to No Limit.
- 36 -
Gemstart 5
Configurable Delay to Restart

Immediate Auto-Restart if
supply
returns
within
configurable Ride Through
time 40ms 5s
Motor supply voltage monitoring for Auto-Restart
- 37 -
0 99m59s for Auto-Restart.

Only enabled if supply returns
within configurable Max Dip
Time 0.5 60 seconds.
Gemstart 5
6.3.12
Pt100 RTD inputs
An RTD input unit (Resistance Thermometry Device) is available to complement the

protection of all Gemstart units. This input module provides 6 channels of inputs
suitable for 2 or 3 wire Pt100 temperature sensors. In addition there are 4 multi
voltage digital inputs.
Each RTD channel measures the resistance of an IEC 60751 standard platinum
resistance element that has a nominal resistance of 100 ohms at 0 degrees
Centigrade. Temperatures between 0 degrees Centigrade and +250 degrees
centigrade can be measured. If three wire connections are used, lead compensation
is automatically performed up to 30 ohms.
The Gemstart unit reports the temperature in Degrees Centigrade of each Pt100.
Protection levels and actions can be configured for each individual element. The fault
level is set in degrees centigrade with a fault severity of LTRIP, TRIP, ALARM or
WARN. In addition a pre warning level can be set to indicate if the motor temperature
is close to tripping.
It is possible to group three sensors together. This allows all three to have identical
settings and they can be used for protecting stator windings, low speed windings,
high speed windings or bearings.
The inputs will also perform diagnostics and report any open circuit or short circuit
condition.
Suitable shielded cable must be used and earthed, preferably at the switchboard.
A protection can be configured in case of the loss of communication between the
IP/RTD module and the Body Unit (no protection, warn, alarm, trip, latched trip).
A typical wiring scheme for the RTD unit is shown below.
Please note it is recommended that 3 wire connections are always used as lead
resistance can cause significant errors in the measurement of the temperature. If 2
wire connections are used then the RTD + and RTD + Sense terminals should be
linked together at the device
- 38 -
Gemstart 5
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
RTD 1 +
RTD 1 RTD 1 + Sense
RTD 2 +
RTD 2 RTD 2 + Sense
RTD 3 +
RTD 3 RTD 3 + Sense
RTD 4 +
RTD 4 RTD 4 + Sense
RTD 5 +
RTD 5 RTD 5 + Sense
RTD 6 +
RTD 6 RTD 6 + Sense
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
RTD 1 +
RTD 1 RTD 1 + Sense
RTD 2 +
RTD 2 RTD 2 + Sense
RTD 3 +
RTD 3 RTD 3 + Sense
RTD 4 +
RTD 4 RTD 4 + Sense
RTD 5 +
RTD 5 RTD 5 + Sense
RTD 6 +
RTD 6 RTD 6 + Sense
3 wire connections (recommended)
6.3.12.1
2 wire connections
Installation
It is important to ensure a clean installation of the RTD sensors as the signal levels
involved are very low.
Each PT100 element should be screened with either a braid screen or foil screen.
Earthing of the screen should be applied both at the Pt100 element and at the
- 39 -
Gemstart 5
switchboard.
Ideally the plant wiring should also be enclosed in earthed, armoured cable.
Connections within the switchboard should ensure that unshielded connections are
kept to a minimum and that all wiring is shielded even within the switchboard. It is
permissible to earth the shield locally within a chassis, separately to the RTD element
The wiring connecting to the PT100 sensor should be sized to ensure that the DC
resistance is kept below 30 ohms in each cable. This is to ensure that the RTD unit
can compensate for the additional cable resistance.
6.3.12.2
RTD Configuration
The RTD can measure a range of temperatures and each temperature input requires
a pre warn and fault level. It will be possible to group three RTDs together to allow a
common configuration setting for all three (i.e. bearings). The group settings will be
held in RTD 1 or RTD 4. When RTDs are grouped the highest RTD temperature will
be used to perform the protection.
The Fault must be configurable from 105C to 180C in steps of 5C (16 options)
The pre warn can be Off or provide a warning at a temperature of 5, 10 or 15C lower
than the fault level.
It will also be possible to disable each RTD (no error reporting).
- 40 -
Gemstart 5
The loss of link between the RTD module and the input module can be protected (no
protection, warn, alarm, trip, latched trip). Select module type in Fuses and
Contactor and the protection severity. Note : Select carefully the right module; if
RTD module is selected and IP is fitted, protection will be engaged.
- 41 -
Gemstart 5
6.3.12.3
RTD Status Reporting (GEMPRO)
The status is displayed on GEMPRO. Access is via the temperature sensors button.
For these three cases, protection will work:
If the RTD measures > 264 then the warning message RTD x Open
circuit is displayed.
If the RTD measures <88 then the warning message RTD x Short circuit
is displayed.
If the RTD measures >= 194 < 264 then the warning message RTD x
High Temp.(>250C) is displayed.
For these two cases, input channel will be ignored:
If the RTD is not connected when starting the application then the warning
message RTD x Not connected is displayed.
If the RTD measures >88 <= 100 then the warning message RTD X Low
Temp.(<0C) is displayed
Note : Disconnection during application running will lead to Open circuit.
If the groups are enabled then the relevant text will show the highest temperature in
the group.
The diagram overleaf shows the wiring fault conditions
No valid temperature in group 1

No sensing element connected
Sensing element short circuit
Wiring fault
Maximum temperature in group 2
Temperature low
Temperature high
- 42 -
Temperature with set point
Gemstart 5
Input +
100<R>250
ohms
Input -
Input +
sense
Working connection
Input +
Input +
Input -
Input -
Input +
sense
Input +
sense
Short circuit
Short circuit (2)

Input +
Input +
Input -
Input -
Input +
sense
Input +
sense
Not Connected (1)
Not Connected (2)
Input +
Input -
Open circuit
Input +
sense
88< R<= 100 ohms
Input +
Input +
Input -
Input -
Input +
sense
Input +
sense
Unused inputs
Low temperature
- 43 -
Gemstart 5
6.3.12.4
RTD Status Reporting (Network)
Information previously explained is also available in a data word over the network. It
is the Word 5 of Group 11 (dedicated to RTD). This word is called RTD Status and is
decoded using the following table :
6.3.12.5
RTD Fault Reporting (Fault log and serial link)
This is the information available via the Fault log

Fault reporting is enabled on each channel individually (unless groups are used)
using the active box. In normal operation the only reports will be an Over temperature
fault. The severity of this is configurable.
RTD # Over Temp. Trip # is the RTD input number (1 to 6). The severity can be
configured.
If the temperature is over the fault limit then an Over Temperature fault is indicated.
Six new fault codes will be created.
If there is a fault with the external wiring then a Warning will be reported. One of the
following is applicable
RTD # Open Circuit # is the RTD input number (1 to 6). The severity can be
configured.
Open Circuit is indicated if the resistance goes very high or there is no connection.
RTD # Short Circuit # is the RTD input number (1 to 6). The severity can be
configured.
Short Circuit is indicated if the resistance goes very low.
RTDs 1, 2 and 3 and/or 4, 5 and 6 can be grouped together. When they are grouped
- 44 -
Gemstart 5
then the individual channel protection is disabled and a group fault code is generated
if the temperature for any of the RTDs in the group is over the configured level.
NB When group protection is enabled Open or Short Circuit faults are generated for
any of the RTDs in the group.
Between the 2 groups there are 6 fault codes that can be generated. The severity of
these faults is configurable.
Group 1 RTD Trip
Group 2 RTD Trip
Bearings RTD Trip
Stator RTD Trip
Low Speed RTD Trip
High Speed RTD Trip
These faults will be generated instead of an RTD fault if the RTDs are grouped.
On the network, RTD values are on one byte and correspond to:
0 = low temperature (<0C)
1-250 = temperature value in C
251 = high temperature (>250C)
252 = group value not available (e.g. all probes in this group are short-circuit)
253 = open circuit (e.g. a probe has been deplugged during functionning)
254 = probe short-circuit
255 = not connected (at gemstart startup, no probe has been detected)
- 45 -
Gemstart 5
7 Display Modules
There are two display modules, the LED module and the LCD module. These units
are mounted on the front panel of the chassis and fit a standard 68mm square, meter
size cut-out. They are wired to the body unit using an 8 core cable with RJ45
connectors. This cable supplies the power from the body unit to the display module
and transfers data between them.
LCD Module.
LED Module.
Common Features:
LED 1 = Green Healthy/Watchdog LED. This turns off if there is a hardware/software
fault and the contactor opens. It is advised to proceed to the remplacement of the
drawer in this case.
LEDs 2 to 5 = 4 x tri-coloured, Red/Green/Yellow LEDs.
LEDs 2 -5 are pre-assigned to the following status conditions:
LED 2 = Running - LED red = contactor closed, LED off = contactor open
LED 3 = Stopped - LED green = contactors open and no current flowing, LED off =
contactor closed or current flowing.
LED 4 = Tripped/Alarm
LED red = Tripped or LED red flashing = Latched trip.
LED yellow = Warn or LED yellow flashing = Alarm
- 46 -
Gemstart 5
LED OFF = no fault.
Note: A Latched Trip or an Alarm needs to be reset (see section 7.2 for ways to
reset), whereas a Trip or a Warn are self clearing. The resetting or self clearing of a
fault is only possible once the source of the fault has been cleared. However, an
Alarm caused by a protection trip will reset automatically once the source of the fault
has been cleared and a successful start has been achieved. If both a Trip and Alarm
are present simultaneously, the Trip will take precedence.
LED 5 = Serial Link - LED yellow = Link active but not in control or LED green = Link
active and in control or LED off = no link.
However, LEDs 2 to 5 can be freely assigned to any one of the different function
options which are available. In addition, all four LEDs are user configurable to any
one of the three colour states. The LEDs can be configured to be On or Off for
function on or function off indication.
e.g. LED Off/Green = Function Off/Function On and LED Green/Off = Function
Off/Function On.
The following table lists all the functions available and their auto (default) colour
configuration.
Function
Serial Mode
LED with Auto colour selected
Function Status
Off = No link
OFF
Yellow = Link active but not in serial link control
OFF
Green = In serial link control
ON
Off = Manual not active
OFF
Yellow = Manual active but not in control
OFF
Green = In manual control
ON
Off = Local not active
OFF
Yellow = Local active but not in control
OFF
Green = In local control
ON
Off = Remote not active
OFF
Yellow = Remote active but not in control
OFF
Green = In Remote control
ON
Off = Current flowing or contactor closed
OFF
Green = Contactor(s) open and no current flowing
ON
Off = Contactor A or B open
OFF
Red = Contactor A or B closed
ON
Running A
Off = Contactor A open
OFF
(fwd, low, star, close)
Red = Contactor A closed
ON
Running B
Off = Contactor B open
OFF
(rev, hi, delta, open)
Red = Contactor B closed
ON
Manual Mode
Local Manual Mode
Remote Manual Mode
Stopped
Running (A or B)
- 47 -
Gemstart 5
Function
Avail to Manual
LED with Auto colour selected
Off = Test position, interlock, hard stop, emergency OFF

start, Not in manual.
Green = A manual start/stop will start/stop the motor
Avail to Host
Test
Current
Auto
ON

start
Green = A priority start/stop will start/stop the motor
Fault
ON

start, not in link control
Green = An auto start/stop will start/stop the motor
Avail to Priority
Function Status
ON
Off = No fault
OFF
Yellow = Warn
ON
Yellow flashing = Alarm
ON
Red = Trip
ON
Red Flashing = LTrip
ON
Off = Not in test position
OFF
Yellow = In test position
ON
Off = Stopped
OFF
Yellow (On) = i < undercurrent level
ON
Green (On) = i < 100%FLC
ON
Red (On) = i > 100%FLC
ON
LED 2. Running, as above

LED 3. Stopped, as above
LED 4. Tripped, as above
LED 5. Serial Mode, as above
See Display item under the Configuration Editor for full settings options.
There is also the option to display current on a single LED as None (Off), Low
(Yellow), Normal (Green), and High (Red).
Easy knockout plugs are provided as standard for the option to fit 16mm diameter
push buttons. One can be fitted on the LCD module or up to three on the LED
module.
The display modules are designed to allow self-adhesive labels to be affixed to
identify customised LED and push button configurations.
The RS232 programming port allows Flash Memory updates of Gemstart 5
software and configuration changes, both using the PC Programming
Tool/Configuration Editor.
- 48 -
Gemstart 5
7.1 Display data configuration.

The LCD module also includes a 128 x 64 pixel, back lit graphical display, to provide
local display of Gemstart 5 information. The display can be in English (UK), French,
German or a User Defined language (Norwegian has been deleted from base
languages but can be reintegrated as User Defined Language). The required
language required can be selected from the Configuration Editor.
The data and format displayed is configurable using the Configuration Editor.
Running A
Status
415V, 123.4kW, 0.66
Voltage and Power
90%,
90%,
90%FLC FLC Currents
LINE 1
2
3
4
5
Thermal Overload Tri Scrolling Primary fault

3 ALC Warn.3/3 Imbal Rotating list of other faults
101: 12-GM-3456
Link address and Tag Number
L1-2= 415V
Voltage
123.4A,123.4A,123.4A AMPS
235Hr,
612 Ops Hours and Operations
No Faults
SCROLLING PRIMARY FAULT
Rotating list of other faults

101: 12-GM-3456
L1^100%FLC
Highest Percentage
6
7
LINE 1
2
3
4
5
6
7
LINE 1
2
3
415V, 123.4kW, 0.66
Voltage and Power
No Faults
Scrolling Primary fault
4
5
Rotating list of other faults

101: 12-GM-3456
Typical example of Gemstart 5 data on graphical display.
- 49 -
6
7
Gemstart 5
7.2 Gemstart 5 Fault Messages

All fault messages are displayed on both the LCD display and in the FAULTS item
window in the GEMPRO control tool. Refer to the list below for the full meaning of the
message.
The ~ symbol indicates where the severity text (Warn, Alarm Trip, LTrip) is placed.
Warn is a self clearing message
Alarm is a latched message. Reset Faults to clear.
Trip is a self clearing trip. The motor is stopped and cannot be started until the trip
source is cleared.
LTrip is a latched trip. The motor is stopped and cannot be started. Reset Faults to
clear the fault. If the fault is still present the fault message cannot be reset.
The reset groups are:
T: Thermal Protection
M: Motor Protection
A: Application Protection
I: Interlocks
E: Earth Protection
There are a number of ways that the Resets can be carried out, namely:
Reset Faults using PC Control tool in Monitor Mode
See Configuration Editor, GEMPRO item for configuration options.
Reset Faults using PC Control tool in Control Mode - Resets all Faults as well as
individual Statistics with Reset buttons shown beside certain items displayed by
GEMPRO. e.g. maintenance data.
Reset Faults using the Reset Input function
See Configuration Editor, Digital Inputs item for configuration options.
Reset Faults from release of Stop button
See Configuration Editor, Manual Controls item for configuration options.
Reset Faults using the Communications Host Operator
See Configuration Editor, Communications item for configuration options.
Reset Faults using the Communications Host Supervisor
See Configuration Editor, Communications item for configuration options.
- 50 -
Gemstart 5
SEVERITY
Gemstart 5 Fault Messages list
Unknown Fault Code ~.
Config. Conflict ~.
Trip
Isolator Fault ~.
Config.
Undefined Fault ~.
Earth Fault ~.
Config.
The configured mode of earth fault

detection has detected an earth fault
Thermistor Relay ~.
Config.
The thermistor relay

GEMSTART is active
Overload Relay ~.
Config.
The external thermal overload relay is

active
Thermal Overload ~.
Config.
The estimated thermal content of the

motor is over 100%
RESET
GROUP
FAULT MESSAGE
FAULT
CODE SENT
DOWN
SERIAL LINK
An unknown fault code is present. Use

GEMPRO see what the fault code is
The configuration in GEMSTART does
not match the configuration passed via
the serial link
I
The isolator is off

Undefined fault. This is a general fault
message
provided
for
future
compatibility
9
Manual Stop ~.
MEANING
input
to
Not Used
10
The manual Hard Stop input is active

and GEMSTART is NOT in Manual
mode. The Fault is self clearing
Trip
11
Not Used
Interlock ~.
12
Config.
An external emergency stop or

interlock has removed the supply for
the contactors
Failed to Close A ~.
13
Trip &
Alarm
GEMSTART could not close contactor

A. The state of contactor A is derived
from the Auxiliary input
Failed to Close B ~.
14
Trip &
Alarm

B. The state of contactor B is derived
Failed to Open A ~.
15
Trip &
Alarm
GEMSTART could not open contactor

A. The state of contactor A is derived
Failed to Open B ~.
16
Trip &
Alarm

B. The state of contactor B is derived
- 51 -
Gemstart 5
FAULT
CODE SENT
DOWN
SERIAL LINK
RESET
GROUP
FAULT MESSAGE
SEVERITY
MEANING
PAMM Read/Write ~.
17
Config.
The unit has failed to read or write to

the PAMM. This fault occurs whilst
power is valid and no data has yet
been lost
Release Manual Start

~.
18
Warn
One of the manual start inputs is

active but the relevant contactor is
open
Current Flow While

Open ~.
19
Trip &
Alarm
Fwd/Rev ~.
20
Warn
A request to close has been received

while the opposite contactor is closed
A host close command is being
received in Auto or Priority mode and
the contactor is open. A Start edge
must be seen to generate a start
command
Both contactors are open but current

flow to the motor has been detected
Release Host Start ~.
21
Warn
Under Current ~.
22
Config.
The motor current has been below the

configured under current level for the
configured time
Start Current ~.
23
Config.
The current during startup exceeded

the configured limit
Start Time ~.
24
Config.
The start time has exceeded the

configured limit
Continuous ALC ~.
25
Config.
The current was above the continuous

ALC level for longer than the
configured time
Instant ALC ~.
26
Config.
The current reached the instant ALC

limit
Restart inhibit. The motor can be

restarted in xxxxs. This is the
estimated time to reach the point
where a successful start can be
completed.
GEMPRO
displays
"Restart Inhibit", Gemstart displays
Available xxxxs
Restart Inhibit ~.
27
Trip &
Alarm
28
ELCB Fault ~.
29
Not Used
Config.
- 52 -
The input assigned as ELCB fault has

detected a fault condition
Gemstart 5
AutoRestart ~.
FAULT
CODE SENT
DOWN
SERIAL LINK
RESET
GROUP
FAULT MESSAGE
SEVERITY
MEANING
Contactor will be closed by the auto

restart function in xxxx seconds.
GEMPRO displays "Auto Restart
Warn". Gemstart displays Restart
xxxxs
30
Warn
Imbalance ~.
31
Config.
The configured imbalance level has

been detected
Single Phasing ~.
32
Config.
An imbalance of 80% has been

present for the configured time
Power Factor High ~.
33
Config.
The power factor is above the power

factor high level
34
Config.
The power factor is below the power

factor low level
Overload Reset Delay

~.
35
Trip
Time remaining after an overload

condition
before
GEMSTART
becomes available
Device Fault ~.
36
Config.
The device connected has reported a

fault (i.e. breaker, VSD etc.)
User Text Message 1
37
Config.
User defined text input 1 has become

invalid
User Text Message 2
38
Config.
User defined text input 2 has become

invalid
Power Factor Low ~.
One of the Chassis Definition

configuration items has changed
during a power down. This means the
chassis has been moved to a new
PAMM. Check the chassis settings
before resetting the fault
Chassis Settings
Changed ~.
39
Warn
Failed to Close C ~.
40
Trip &
Alarm

C. The state of Contactor C is derived
from the auxiliary input
Failed to Open C ~.
41
Trip &
Alarm

C. The state of Contactor C is derived
from the auxiliary input
Unexpected Open A ~.
42
Trip &
Alarm
Contactor A opened when it was not

expected. The state of Contactor A is
derived from the auxiliary input
Unexpected Open B ~.
43
Trip &
Alarm
Contactor B opened when it was not

expected. The state of Contactor B is
- 53 -
Gemstart 5
FAULT MESSAGE
FAULT
CODE SENT
DOWN
SERIAL LINK
SEVERITY
RESET
GROUP
MEANING
Unexpected Open C ~.
44
Trip &
Alarm
Contactor C opened when it was not

expected. The state of Contactor C is
Unexpected Close A ~.
45
Trip &
Alarm
Contactor A closed when it was not

expected. The state of Contactor A is
Unexpected Close B ~.
46
Trip &
Alarm
Contactor B closed when it was not

expected. The state of Contactor B is
Unexpected Close C ~.
47
Trip &
Alarm
Contactor C closed when it was not

expected. The state of Contactor C is
Changeover Timeout ~.
48
Trip &
Alarm
The requested change from FWD to

REV or STAR to DELTA has failed
due to current still flowing or the
contactor not opening
Phase Reversal ~.
49
Config.
The phases are not rotating or not

rotating in the correct order
Starts/Hr ~.
50
Config.
The number of starts per hour has

been exceeded. A warn is issued
Unknown Contactor
Type ~.
51
Alarm
Over Voltage ~.
52
Config.
The supply voltage is above 110% of

the nominal voltage
Under Voltage ~.
53
Config.
The supply voltage is below 90% of

the nominal voltage
Test Mode ~.
54
Config.
GEMSTART has been withdrawn to

the test position
The configured contactor type is not

available to this unit
Host Link Lost ~.
55
Warn or
Trip
The serial link has timed out but bytes

are still being received. The timeout
time varies with the link speed.
GEMSTART will cycle through the
baud rates in an attempt to find a valid
message
No GS RX ~.
56
Warn
No Bytes received from Host (Link fail)
GS RX Crossed ~.
57
Warn
Failed CRC checks at all baud rates

(Link fail). Suspect that the RX lines
have been crossed
Warn
All baud rates are being scanned to

find a valid link speed. If all rates fail
message changes to GS RX Crossed
Baud Rate Scan ~.
58
- 54 -
Gemstart 5
Address in use ~.
59
Warn
Sequence bit toggling before reply

sent by this unit so another unit is
using this address
TX RX Lines Crossed
~.
60
Warn
Primed by previous message but

failed CRC to this address
Speed Sense ~.
61
Config.
Wrong Host Link ~.
62
Warn
The number of the link does not match

the configured link
Warn
Gemstart
is
not
receiving
acknowledgements from the Host that
it has received a message from
Gemstart. (The sequence bit is not
changing.)
Alarm
The current flowing is too high to open

the contactor. The stop command is
not actioned until the current drops or
the fuse delay has been exceeded
FAULT MESSAGE
GS TX Fault ~.
Stop Delayed.
(Contactor Protection)
PAMM Config Invalid ~.
63
64
MEANING
The Speed Sense input has not been

activated within the required time
65
Not Used
66
Not Used
67
Not Used
68
Not Used
69
Not Used
70
One or more of the 16 configuration

blocks could not be read from the
PAMM. Default configuration has been
used. The default configuration should
be overwritten by GEMPRO when the
link is established. CHECK ALL
CONFIGURATION VALUES BEFORE
RESETTING THIS TRIP
Alarm
71
PAMM Motor Data Lost
~.
RESET
GROUP
FAULT
CODE SENT
DOWN
SERIAL LINK
SEVERITY
72
Not Used
Alarm
The motor data in the PAMM could not

be read. All or some motor data has
been lost
73
Not Used
74
Not Used
75
Not Used
- 55 -
Gemstart 5
Host TX Range ~.
Config Area XSUM ~.
Wrong PAMM ~-Reset

to Clear.
New PAMM ~-Reset
Trips to Initialise
Manual Start and Stop
Active ~.
Unknown Function
Enabled ~.
Under Power ~.
Over Power ~.
CRC Failed ~.
76
Warn
This Gemstart is not in the address

range addressed by the host
LTrip
The configuration data in Gemstart

has been corrupted. CHECK ALL
CONFIGURATION VALUES BEFORE
RESETTING THIS TRIP
77
RESET
GROUP
FAULT MESSAGE
FAULT
CODE SENT
DOWN
SERIAL LINK
SEVERITY
MEANING
78
Not Used
79
LTrip
The PAMM is not a Gemstart 5 PAMM

or is new. Default configuration data is
loaded into GEMSTART. Resetting
TRIPS will load the PAMM with the
default configuration data
80
Warn
The START command will not function

while the STOP input is active
81
Not Used
82
Not Used
83
Alarm
The PAMM has been configured with

a feature which is unknown to this
Gemstart. Update Gemstart Firmware
or replace with a more up to date unit
84
Config.
Under Power Protection has been

activated
85
Config.
Over Power Protection has been

activated
86
Alarm
Program code CRC failed

This fault is generated if there is a
problem with the configuration data.
The number in the message indicates
the first configuration error that
occurred. The codes are:
Config Error ### Warn

~.
87
Warn
10 - The FLC level is too high for the

configured CT.
11 - The primary
unknown.
CT
rating
is
12 - Contactor rating level too high for

the configured CT.
13 - FLC Set too low for the CT (<
0.49A).
14 - ALC Set > FLC.
- 56 -
Gemstart 5
FAULT
CODE SENT
DOWN
SERIAL LINK
RESET
GROUP
FAULT MESSAGE
SEVERITY
MEANING
15 - Start Current limit level too high

for the configured CT.
20 - The difference between EF CT
range and Fault range is too
much.
21 - The EF CT must be defined
before EF fault can be enabled
22 - The ratio of the fault to the EF CT
is too big.
23 - The ratio of the startup fault to the
EF CT is too big.
24 - The EF Fault level is too big for
the EF CT input.
25 - The Residual CT EF Fault level is
too low (below 100mA)
30 - Power set too high.
31 - Power set too low.
32 - Power protection enabled but kW
cannot be calculated
40 Ride-through > Max Dip Time
41
3 CTs
Gemstart5.3
configuration
on
42 Profibus Ampsx100 not valid with

external CT
43 Profibus Powerx100 not valid for
this range
44
Ride-Through = No Limit
incompatible with Volatile Supply
Inputs
100-199 The above faults are

increased by 100 if the error only
exists
in
the
Speed
2
configuration
The fault clears itself once the
configuration problem is resolved.
HV on LV input ~.
88
Alarm
- 57 -
Input wrongly configured or volts too

high for configured voltage level
Gemstart 5
Chassis Input Overload

Warn ~.
89
Warn
PTC Over Temperature
90
Config.
PTC Short Circuit
91
Config.
RTD 1 Over
Temperature
92
Config.
The Pt100 sensor 1 has reached its

set point
RTD 2 Over
Temperature
93
Config.

set point
RTD 3 Over
Temperature
94
Config.

set point
RTD 4 Over
Temperature
95
Config.

set point
RTD 5 Over
Temperature
96
Config.

set point
RTD 6 Over
Temperature
97
Config.

set point
RTD 1 Short Circuit
98
Config.
The Pt100 sensor 1 has failed short

circuit
RTD 2 Short Circuit
99
Config.

circuit
RTD 3 Short Circuit
100
Config.

circuit
RTD 4 Short Circuit
101
Config.

circuit
RTD 5 Short Circuit
102
Config.

circuit
RTD 6 Short Circuit
103
Config.

circuit
RTD 1 Open Circuit
104
Config.
The Pt100 sensor 1 has failed open

circuit
RTD 2 Open Circuit
105
Config.

circuit
RTD 3 Open Circuit
106
Config.

circuit
RTD 4 Open Circuit
107
Config.

circuit
- 58 -
RESET
GROUP
FAULT MESSAGE
FAULT
CODE SENT
DOWN
SERIAL LINK
SEVERITY
MEANING
Common 24v short circuited.
The
temperature
measurement
thermistor has reached its set point
The
temperature
measurement
thermistor has failed short circuit
Gemstart 5
RTD 5 Open Circuit
108
Config.

circuit
RTD 6 Open Circuit
109
Config.

circuit
Group 1 RTD
110
Config.
One sensor in Group 1 has reached

its set point
Group 2 RTD
111
Config.
One sensor in Group 2 has reached

its set point
Bearings RTD
112
Config.
One sensor in the bearings Group has

reached its set point
Stator RTD
113
Config.
One sensor in the stator Group has

reached its set point
Low speed RTD
114
Config.
One sensor in the Low speed Group

has reached its set point
High speed RTD
115
Config.
One sensor in the High speed Group

has reached its set point
IP/RTD module lost
116
Config.
Module link cut or IP IC circuit or RTD

IC circuit not functionning
FAULT MESSAGE
RESET
GROUP
FAULT
CODE SENT
DOWN
SERIAL LINK
SEVERITY
MEANING
7.3 Gemstart Fatal Errors

There are some fault conditions that Gemstart cannot operate normally. These
conditions are called FATAL ERRORS. When a Fatal Error occurs Gemstart will
display a message indicating what the Fatal Error is.
Fatal Error Text
Description of Fault
During Power Up:

PAMM MISSING.
The PAMM was not detected when Gemstart powered up. Note only
if External PAMM required.
Both PAMMs Missing
The PAMM and internal PAMM backup are not present or working.
Check PAMM wiring.
Hardware Faults
Oscillator Fail
Processor clock fault. Replace the unit. Return for repair.
Internal Memory Fail
Internal (to the processor) memory fault. Replace the unit. Return for
repair.
External Memory Fail
External (to the processor) memory fault. Replace the unit. Return
for repair.
Software Faults:
- 59 -
Gemstart 5
Fatal Error Text
Description of Fault
Unexpected Reset
These are traps put in to catch software design problems. However

they can also be caused by hardware failures. Replace the unit.
Return for repair.
Unexpected RET
Register Corrupted
Stack Underflow
Stack Overflow
Software
0x##@####
Wdog,
It is possible to get a Software WatchDog during a Software

Update. This may happen and is not a problem for the update. It
should disappear at restart.
Not In-Page
PAMM Faults:
Power Down & Replace This is the message displayed when replacing the PAMM using the
PAMM
GEMPRO command, REPLACE PAMM.
PAMM Wiring Fault
Gemstart has detected a problem with the PAMM data line. Check
the PAMM wiring.
- 60 -
Gemstart 5
8 Watchdog Functions
There is a green Healthy LED on all Gemstart body units which will flash at a slow
rate of approximately once a second, indicating that the unit is working correctly. If
there is a hardware or software failure this will cause a system Watchdog trip and this
LED will flash at a much faster rate of approximately four times a second.
On the display modules and on each extension module the green Healthy LED is
illuminated when the units are working correctly, but if there is a hardware or
software failure the system Watchdog trips and this LED is turned Off.
The system will also disable the serial link transmit, if connected, and disable the
output relays for a Watchdog trip.
In the unlikely event of the Watchdog being activated, firstly see if the LCD display, if
one is present, has reported an error message, such as Hardware or Software
Failure. If it is software it may be possible to reset the Gemstart by powering down
the unit and turning it back on again after 60 seconds. Any hardware or software fault
must be reported to COMECA for investigation.
- 61 -
Gemstart 5
9 Event Records
9.1 Motor History
A history of the last 16 trips that opened the contactor is maintained. Each entry has
the value of current, reason for trip, and the elapsed time since the trip occurred. The
records are overwritten on the first in first out principle (FIFO).
9.2 Event History

A history of the last 16 sources of contactor operations is recorded, including the
elapsed time from the issue of the recorded command and the source of the
command. e.g. Priority Start B, Manual Stop A, Local Start A, Overload Trip. The
event history does not record current. The records are overwritten on the first in first
out principle (FIFO).
9.3 Plant Associated Memory Module (PAMM)

Gemstart 5 has the option of an Onboard PAMM located within the Gemstart 5 body
unit or it can have an external PAMM mounted within the motor chassis or feeder
cubicle. The advantage of the external PAMM is that it can be located within the motor
chassis or the circuit breaker cubicle and it will remain with it for its lifetime, regardless
even if the Gemstart unit needed to be replaced or upgraded.
The Gemstart 5 PAMM allows you to hold the settings configuration and event
records in a designated, non volatile memory chip. This memory is continuously
updated so that all data in the PAMM will be no more than 30 seconds old.
- 62 -
Gemstart 5
10 System Integration
A range of communications protocols are available for networking Gemstart 5s with
an intelligent control system, using either a 2 or 4 wire multi-drop RS485 serial link
:
Modbus (up to 127 devices per link)
Profibus DPV1 (up to 125 devices/ 32 per bus section)
Gembus (COMECAs proprietary protocol) (up to 100 devices/ 100 per link)
All the above protocols come pre-loaded into Gemstart 5 and may be selected under
item Communications using the Configuration Editor.
10.1 Modbus Interface

This section describes Gemstart when running on a Modbus link.
A serial link connection is provided for you on each Gemstart to allow a Host to
remotely control and interrogate it for performance data. Gemstart 5 with Modbus
communicates over a 2 or 4 wire, RS485 link.
The following Modbus functions have been implemented:
1 & 2, Multi Bit Reads
3 & 4, Multi Word Reads
5,
Single Bit Write
6,
Single Word Write
7,
Read Exception Status
8,
Traffic Diagnostics
Sub Functions
0
Loop Back Test
10
Reset Counters 1 to 9
11
Read Counter 1, Bus Messages
12
Read Counter 2, CRC Errors
13
Read Counter 3, Bus Exceptions
14
Read Counter 4, Slave Messages
15
Read Counter 5, Broadcast Messages
16
Read Counter 6, Not Used
17
18
11,
Read Event Counter (Modbus Counter 9)
15,
Multi Bit Write
16,
Multi Word Write
- 63 -
Gemstart 5
10.1.1
Configuration of the Serial Link
Some aspects of the Modbus serial link cannot be changed. These are:
Start Bits
Data
Parity
None
Stop Bits
Modbus Type
RTU
End of message gap
3 characters
Gap before reply
At least 2ms (max. 20ms)
Additional Information
Link Timeout Time
2 seconds
Auto Detect Timeout
1 seconds
Max Register Write Length
8 registers
(NB Configuration Data must be written 8 registers at a time)

Max Bit Read/Write Length
128 bits
Max Register Read Length
64 registers
There are some aspects of the Modbus serial link that can be configured for each
Gemstart. These configuration parameters are:
Protocol (Communications/Protocol)
Select Modbus. Select 2 or 4 wire option. Note if the link address is set to 0 then
Modbus is not offered as this is an illegal address. Defaults to Profibus. The Profibus
options is discussed elsewhere.
Link Fail Action(Communications/Link Fail Action)
Gemstart can take action on a Serial Link failure. The link fail action is taken if the
serial link was controlling Gemstart when the link failed. The options are:
Trip:
Open the Contactor and report a Link Trip message;
Warn:
Leave the Contactor unchanged and report a Link Warn message;
Off:
No action. Leave the Contactor unchanged. No Link fault reported.
With Modbus the link has failed when Gemstart has not seen a valid message to any
address within the timeout time.
Configurable Host status bits(Communications/Status Bit Source)
Two bits are available in the status word, which may be separately configured to any
of the inputs of Gemstart 5. The available options for these bits are Disabled, Active,
INTERLOCK, INPUTS 1- 12, and OUTPUT 4.
Group 10 (Communications/Group 10 Word x)
A configurable data group has been provided. This allows the user to select items
from the 10 fixed groups which are grouped together in adjacent addresses as group
- 64 -
Gemstart 5
10.
Control Group (Communications/Control Group)
Define which Control Group this Gemstart is a member of. Options of Off and groups
1 to 7 are available. A Modbus Host can write (to register address 3) a Group Control
command to control several Gemstarts at the same time. This command contains a
standard 4 bit contactor control command and 7 Group Flags. If the Group Flag
corresponding to this Gemstarts group is set, then Gemstart will copy the 4 bit group
command to the command register (address 1). While the Group Flag is set the
Group Command is used regardless of what is written to address 1.
Link Number and Address (Communications/Address)
This value identifies a specific Gemstart on the Link. It can only be altered using
GEMPRO to change it from Not Set to the desired address. Once the address is set
only COMECA engineers can change the address. This protects the address from
accidental changes. Valid address values are 1 to 254.
Fixed Baud Rate(Communications/Baud Rate)
You can connect Gemstart to links running at 4800, 9600, 19k2, 38k4, 57k6, 115k2
and 128k baud. Gemstart can auto search for the baud rate of the link to which it is
connected or can be configured to always run at 115k2, 9600 or 19k2. Fixing the
baud rate means that time is not wasted searching for messages at the incorrect
rate.
Fixed Timeout (Communications/Fixed Timeout)
The serial link Fixed Timeout time has 4 options.
2.5s
5s
10s
20s
These options fix the timeout regardless of the baud rate. The timeout time is the
time between valid messages to any address seen on the link.
10.1.2
Commands sent to Gemstart via the Serial Link
The command sent to Gemstart consists of 3 registers. These are:

Contactor Command
Resets and GP Outputs
Group Control
- 65 -
Gemstart 5
Contactor Command
Gemstart can be controlled via the contactor command using the codes listed in
Table 14:
Table 14 Serial link contactor command codes
Bits 3-0
Command
Mode
0000
0001
0010
0011
0100
0101
0110
0111
1000
1001
1010
1011
1100
1101
1110
1111
Stop
Close A
Close B
No Action
Reserved
Reserved
Reserved
Reserved
Stop
Close A
Close B
No Action
Reserved
Reserved
Reserved
Reserved
Auto
Auto
Auto
Auto
Auto
Auto
Auto
Auto
Priority
Priority
Priority
Priority
Priority
Priority
Priority
Priority
Close A and Close B will mean different things to different contactor models (for
example Forward/Reverse, Low/High Speed, Close/Open Valve).
When Gemstart is operating as a General Purpose I/O device, bits 3 to 0 are the
requested states for outputs D, C, B, A respectively. There is no priority mode on a
General Purpose I/O device.
A close command is edge triggered. I.e. the command is only actioned when it first
appears. If a close command is present and the contactor is not closed then an Open
Required Fault is reported by Gemstart. This fault can be cleared by sending an open
command until the fault clears then send the close command again. Alternatively
close the contactor with the GEMPRO control program.
Resets and I/O Functions byte
Six bits of this field are relevant to you. These six bits include four GP Output bits and
two reset bits.
Table 15 - Reset and General Purpose Outputs Byte
Bit
Command
0
1
2
3
4
5
General Purpose Output A

General Purpose Output B
General Purpose Output C
General Purpose Output D
Operator Reset
Supervisor Reset
For non GP I/O contactor types any spare outputs can be configured (Fuses &
Contactors) to output the GP O/P bits received from the host.
- 66 -
Gemstart 5
The function of the Reset from Host Supervisor and Reset from Host Operator bits
depends on configuration (Communications). A range of individual resets can be
assigned to each of these bits, as given below:
Reset All
All reset functions as defined below
Thermal Overload
Reset overload faults without resetting other motor

protection faults
Motor Protection(inc. O/L)
Start Time, Start Level, Thermal Overload, Ops per

hour etc.
All ALC based protection & phase reversal
Interlocks
Failed to close, Unexpected open, and User defined

text faults
Alarms
All alarms
As a default the Host operator will be allowed to reset:

Alarms, Overloads and Application protection
As a default the Host Supervisor will be allowed to reset:
Alarms, Overloads, Motor protection and Application protection
10.1.3
Data available from Gemstart 5
These tables show the Address for each variable.

Exception Status Bits
Reading the exception status register will return the following bits.
Bit
0
1
2
3
4
5
6
7
For all Contactor Types

Set if Any Trip active (latching or self clearing)
Set if any Fault Present (non zero fault code)
Set if in motor startup phase
Set if open required from Host
Working Contactor A State
Working Contactor B State
Set if motor Stopped (Contactors open and current low)
Set if motor available to Host (i.e. no trips, in auto or priority modes, and not
in test position)
Bit Map
The following data bits can be read. Some of the bits can also be written to.
Address
read/Write
For non GPIO Contactor Types
For GPIO Contactor Type
Read / Write
Start A (Start A AND Start B active = No Action)
Close A
Read / Write
Start B (Start A AND Start B active = No Action)
Close B
Read / Write
Reserved - leave at 0
Close C
Read / Write
Priority Select
Close D
Read / Write
GP Output A
Read / Write
GP Output B
- 67 -
Gemstart 5
Address
read/Write
For non GPIO Contactor Types
Read / Write
GP Output C
For GPIO Contactor Type
Read / Write
GP Output D
Read / Write
Reset from Operator
10
Read / Write
Reset from Supervisor
11
Read
Set if Any Trip active (latching or self clearing)
12
Read
Set if Any Alarm is active
13
Read
Set if Any Warn is active
14
Read
15
Read
Set if Latching Trip Active
16
Read
17
Read
18
Read
Working Contactor A State (Same as Running A LED)
19
Read
Working Contactor B State (Same as Running B LED)
20
Read
Set if motor Stopped (Contactors open and current low - same as Stopped LED)
21
Read
Configurable Host Status Bit 1, defaults to HW Interlock input
22
Read
Set if in or requesting manual mode.
23
Read
Configurable Host Status Bit 2, defaults to Hardware Input 2
24
Read
GEMPRO is in or Requesting Local Control
25
Read
Set if motor available to Host (i.e. no trips, and in auto or priority modes, and not in test
position)
26
Read
HW Interlock input
27
Read
Hardware Input 1
28
Read
Hardware Input 2
29
Read
Hardware Input 3
30
Read
Hardware Input 4
31
Read
Hardware Input 5
32
Read
Hardware Input 6
33
Read
Hardware Input 7
34
Read
Hardware Input 8
35
Read
Hardware Input 9
36
Read
Hardware Input 10
37
Read
Hardware Input 11
38
Read
Hardware Input 12
Word Map
The following words can be read from Gemstart. Some of the addresses can also be
written to. All values are unsigned 16 bit numbers unless indicated otherwise.
Address
Data
Command
R/W
2
Description
Bit 0,1 command; bit 3 is priority. Bit 2 reserved - leave as 0.
Command 00 = stop, 01 = start A, 10 = start B, 11 = no action.
Reset & I/O
Bit 0 to 3 are GP Outputs A to D. Bit 4 is operator reset, bit 5 is supervisor reset.
Group Control
Bits 0-3
R/W
3
R/W
Contactor command - same format as address 1
Bits 4-7
Reserved
Bit 8
Group 1. Set to get Group 1 Gemstarts to obey the command in bits 0-3.
Bits 9-14 Groups 2 to 7. Same as bit 8.
- 68 -
Gemstart 5
4
Status Bits
Bit 15
Reserved
Bit 0
Reserved for Host to indicate Not Responding
Bit 1
Any trip active (Self Clearing or Latching)
Bit 2
Alarm Active
Bit 3
Warn Active
Bit 4
Fault present (Fault code is non zero)
Bit 5
Latching Trip Active
Bit 6
Motor in Startup phase
Bit 7
Open Required from Host
Bit 8
Contactor A State
Bit 9
Contactor B State
Bit 10
Motor Stopped (contactors open & current is low)
Bit 11
Configurable Host Bit 1 (defaults to Interlock I/P)
Bit 12
In or requesting Manual Control
Bit 13
Configurable Host Bit 2 (defaults to I/P 2)
Bit 14
GEMPRO is in or requesting control
Bit 15
Motor available to Host

(no trips, link control, not in test)
Display Data
The value being displayed on Gemstart. NB if 12.34 is being displayed 1234 will be in this
location.
Fault Code
The high byte is the severity the low byte is the fault code.
Address
Data
Description
ALC Current (%ALC)
Grp1:1. Highest phase current as % of ALC
FLC Current (%FLC)
Grp1:2. Highest phase current as % of FLC
Earth Fault Current (%EFC)
Grp1:3. Earth Fault current as a percentage of trip level
10
Power (%Rating)
Grp1:4. Average power as % of rated power
11
Power Factor
Grp1:5. (0-100). Divide by 100 to get the power factor
12
Link Timeouts
Grp2:1. Number of Timeouts detected at Gemstart since counter last reset
13
CRC Errors
Grp2:2. Number of CRC Errors detected at Gemstart since counter last reset
14
Input Counter 1 - Thousands
Grp2:3. Input counter 1 divided by 1000.
15
Input Counter 1 - Units
Grp2:4. (0-999) The remainder of input counter 1 divided by 1000.
16
spare
Grp2:5. For future use
17
Hours Run (Hrs)
Grp3.1. The number of complete hours that the contactor has been closed
18
Operations of A (Hundreds)
Grp3:2. The number of operations of contactor A divided by 100.
19
Operations of A (Units)
Grp3:3. (0-99) The remainder of the number of operations of contactor A divided by

100.
20
Starts in last hour
Grp3:4. (0-255) Number of starts during the last hour
21
spare
Grp3:5. For future use
22
Operations of B (Hundreds)
Grp4:1. The number of operations of contactor B divided by 100.
23
Operations of B (Units)
Grp4:2. (0-99) The remainder of the number of operations of contactor B divided by

100.
24
Operations of C (Hundreds)
Grp4:3. The number of operations of contactor C divided by 100.
- 69 -
Gemstart 5
Address
Data
Description
25
Operations of C (Units)
Grp4:4. (0-99) The remainder of the number of operations of contactor C divided by

100.
26
Motor
Supply
(%Nominal)
27
28
29
30
31
Hardware I/O
Voltage
Grp4:5. The motor supply voltage as a percentage of nominal supply voltage

Grp5:5. The state of Gemstarts input and output pins

Bit 0, interlock; bits 1 to 9, Inputs 1 to 9; bits 12 to 15, Outputs 1 to 4.
32
Highest Phase Current (Scaled

Amps)
Grp6:1. Highest phase current. Divide by Highest Current Divider (Group 6, Word
2) to get Amps
33
Highest Current Divider
Grp6:2. Adjust Highest Current (Group 6, Word 1) to put the decimal point in the
correct place. (Values are 1, 10, 100, 1 000, 10 000)
34
Power (Scaled kW)
Grp6:3. Real Power. Divide by Power Divider (Group 7, Word 5) to get kWatts
35
36
Earth Fault Current (Scaled
Grp6:4. Earth Fault Current. Divide by Earth Fault Divider (Group 6, Word 5) to get
Amps)
Amps
Earth Fault Divider
Grp6:5. Adjust Earth Fault Current (Group 6, Word 4) to put the decimal point in the
correct place. (Values are 1, 10, 100, 1 000, 10 000)
37
Startup Time (s)
Grp7:1. Number of seconds for the last successful startup (Note: A successful start
is one with no trip or stop before the current drops below 100%FLC)
38
Peak Startup Current (%FLC)
Grp7:2. Maximum current achieved during last successful startup (%FLC)
39
Auto Restart Timer (1s units)
Grp7:3. Time in seconds before contactor gets auto restarted
40
Imbalance (%)
Grp7:4. Percentage of the highest phase
41
Power Divider
Grp7:5. Adjust kW Power (Group 6, Word 3) to put the decimal point in the correct
place. (Values are 1, 10, 100, 1 000, 10 000)
42
Thermal Content used by start

(%)
Grp8:1. Estimation of heat energy used during last start as a percentage of the fault
level
43
Thermal Content (%)
Grp8:2. Estimation of heat energy in the motor as a percentage of the maximum

level
44
Time to Trip / Available (s)
Grp8:3. Number of seconds before unit trips or becomes available
45
kW hour meter (kWh)
Grp8:4. kWatt hours measured since Watt Hour meter was last reset (0-9999)
46
MW hour meter (MWh)
Grp8:5. MWatt hours measured since Watt Hour meter was last reset (0-9999)
47
Thermal Trip Counter
Grp9:1. Number of thermal trips since counter last reset
48
Imbalance Trip Counter
Grp9:2. Number of imbalance trips since counter last reset
49
Earth Trip Counter
Grp9:3. Number of earth fault trips since counter last reset
50
Other Protection Trip Counter
Grp9:4. Number of other protection trips since counter last reset
51
Reactive Power
Grp9:5. Reactive Power. Divide by Power Divider (Group 7, Word 5) to get kVAR
52
Data Word
Grp10:1. Any one of Grp1:1 to Grp9:5 as configured
53
Data Word
54
Data Word
55
Data Word
56
Data Word
57
Status Bits
Same as Address 4
58
Fault Code
Same as Address 6
59
Data Word
Grp11:1. RTD 1 (MSB) & 2 (LSB) (see 6.3.12.4 for a description of values)
60
Data Word
Grp11:2. RTD 3 (MSB) & 4 (LSB)
61
Data Word
Grp11:3. RTD 5 (MSB) & 6 (LSB)
- 70 -
Gemstart 5
Address
Data
Description
62
Data Word
Grp11:4. RTD Group1 (MSB) &Group2 (LSB)
63
Data Word
Grp11:5 RTD Status (see chapter 6.3.12.4)
Configuration Data
Address
Read/Write
Data
257-264
Read / Write
Configuration Page 0
265-272
Read / Write
273-280
Read / Write
281-288
Read / Write
289-296
Read / Write
297-304
Read / Write
305-312
Read / Write
313-320
Read / Write
321-328
Read / Write
329-336
Read / Write
337-344
Read / Write
345-352
Read / Write
353-360
Read / Write
361-368
Read / Write
369-376
Read / Write
377-384
Read Only
Trip History Data

Address
Read/Write
Data
1025-32
Read Only
Trip History 1 (most recent)
1033-40
Read Only
Trip History 2
1041-48
Read Only
Trip History 3
1049-56
Read Only
Trip History 4
1057-64
Read Only
Trip History 5
1065-72
Read Only
Trip History 6
1073-80
Read Only
Trip History 7
1081-88
Read Only
Trip History 8
1089-96
Read Only
Trip History 9
1097-04
Read Only
Trip History 10
1105-12
Read Only
Trip History 11
1113-20
Read Only
Trip History 12
1121-28
Read Only
Trip History 13
1129-36
Read Only
Trip History 14
1137-44
Read Only
Trip History 15
1145-52
Read Only
Trip History 16 (oldest)
- 71 -
Gemstart 5
Event History Data
Address
Read/Write
Data
1153-60
Read Only
Event History 1 (most recent)
1161-68
Read Only
Event History 2
1169-76
Read Only
Event History 3
1177-84
Read Only
Event History 4
1185-92
Read Only
Event History 5
1193-00
Read Only
Event History 6
1201-08
Read Only
Event History 7
1209-16
Read Only
Event History 8
1217-24
Read Only
Event History 9
1225-32
Read Only
Event History 10
1233-40
Read Only
Event History 11
1241-48
Read Only
Event History 12
1249-56
Read Only
Event History 13
1257-64
Read Only
Event History 14
1265-72
Read Only
Event History 15
1273-80
Read Only
Event History 16 (oldest)
Trip and Event History Format

Each Trip and Event History entry is 8 words (16 bytes) and has the following format
Byte
Offset
Trip History Format
Event History Format
Index of the history entry. For use by Gemstart do not display.
(Msb of
first
register)
1
The decimal point position. 1=6.5535A, Not Used

2=65.535A, 3=655.35A, 4=6553.5A,
(Lsb
of
5=65.535A, 6=655.35kA, 7=6553.5kA,
first
8=65535kA
register)
2
The fault severity. 0=warn, 1=alarm, Event Source

2=trip, 3=LTrip.
0. No Source
1. Protection
2. Serial Link
3. GEMPRO
4. Local Manual Inputs
5. Remote Manual Inputs
6. Emergency
7. Auto Restart
8. Delayed Action
9. Manual Test (manual operation in test
- 72 -
Gemstart 5
position)
10. Manual
3
Event Type
The fault code.
0. No Event
1. Start A
2. Start B
3. Stop
4. Gemstart Power Up
5. Gemstart Power Down
6. Time Synchronised
7. Time Sync Lost
8. Start A Delayed
9. Start B Delayed
10. Stop Delayed
11. Motor Supply Fail
12. Motor Supply Recovery
4
MSB of Highest phase current in Not Used

Amps. See the decimal point position.
LSB of Highest phase current in Not Used

Amps. See the decimal point position.
mmsb of time in seconds since 1/1/1900. e.g. 1/1/200 00:00:00 is 3155673600s
msb
of time in seconds since 1/1/1900.
lsb
llsb
10
msb
of fractions of a second
11
lsb
of fractions of a second
Bit 0 is the Global Sync flag and is set if the PLC time is Globally synchronised.
12
Time Status
0 = Gemstart(no time update since power on)
1 = Synchronised (sync time received in last 100s)
2 = Estimated(no sync time received in last 100s)
3 = Invalid(time was not updated between power up and power down)
13
Spare set to 0
14
Spare set to 0
15
Spare may not be 0.
- 73 -
Gemstart 5
10.1.4
Serial link timeout operation
If no valid messages are received by Gemstart from the Host system within the
timeout period, a Link Fail Trip or Warn is flagged.
Once the link is established the timeout period of each baud rate on the link is 2.5s
except for 4800 which has a timeout of 5s.
The timeout time can be forced for any baud rate to be 5, 10 or 20s. See
configuration item Communications/Timeout
The auto detect method for Baud (and protocol) selection is as follows:
Gemstart will only try a new baud rate if it is receiving bytes but has not received a
valid message for 1.5s
The 1.5s time starts when the first byte has been received after a timeout. When an
active link times out the baud rate is not changed
The normal order of events is as follows:
1.
A healthy link stops transmitting
2.
After the timeout time associated with the baud rate, the link fail action
will occur (trip or warn). The baud rate will not change. No further
timeouts are possible until a byte has been received
3.
The first byte received will start the 1.5s timer
4.
If a valid message is received within 1.5s then the link is re-established
5.
If a valid message is not received, a timeout is recorded and the baud

rate is changed. The mechanism then goes back to step 3
If data is being continuously transmitted by the Host the unit will spend 1.5s at each
baud rate until it receives a valid message.
To keep Gemstart operating in Auto or Priority mode, Gemstart must see a valid
message (to any address) every 2.5s. Given that there is enough activity on the link,
Gemstart will not go into Auto or Priority mode until the command register (address
1) or command bits (address 1, 2 or 4) have been written to.
10.1.5
Serial link performance statistics
Gemstart provides you with the following serial link statistics which can be viewed on
GEMPRO:
10.1.6
Baud rate
The speed the serial link is operating at.
Command
The last command written to address 1 or address 3 with

the relevant Group Flag set. If the Group Flag is still set
then (Grp) is also displayed. While the Group Flag is set
the Group Command is used regardless of what is written to
address 1.
Link
Timeouts
The number of times an expected message to this Gemstart

was not received. Available in Link Info data group and at
the GEMPRO control program
Modbus Link Fault Indications
Gemstart indicates that a Serial Link Fault is present if there is no Modbus link
- 74 -
Gemstart 5
present. If a Modbus link is connected then the Link Fault indication will be cleared.
However Gemstart will not go into Auto or Priority mode until the command register
has been written to.
If the first command write after a link fail is a start command it will not be obeyed as
all commands are edge triggreed and in this case an edge was not seen.
It is therefore important that the Modbus Master continually monitors the status of
each Gemstart and if it sees that a Gemstart is not in Auto or Priotity then the
Modbus Master should write a No Action command to the command register.
10.1.7
Modbus Time Synchronisation
Gemstart 5 time can be synchronised with a broadcast messaged from the master
PLC. The broadcast message should be to address 0x0801 (offset 0x0800) and be 4
registers long. The first byte of the message is taken as the time mark. The format of
the 4 registers of data is as follows:
( Inverted IEC 870-5-4 CP56Time2a):
Words
0
0
0
0
su
0
0
Year
0
00..99
Month
0
WeekDay
DayOfMonth
1..12 1..7 1..31
iv
Minutes
0..23 0..59
0
Hours
Millisecond Hi
215
Millisecond Lo
28 27
0..59 999 (second+milliseconds)

20
Notes:
su = 0 Standard, = 1 Summer Time. Not used by Gemstart.
iv = 0 valid, = 1 non valid or non synchronised in system case
WeekDay is not used by Gemstart.
Dates are from 1/1/2000 to 31/12/2099
To maintain synchronised time the broadcast message should be sent within 100s of
the previous broadcast. An update time of 30s would ensure time synchronisation is
not lost should a broadcast be corrupted.
This Time Synchronisation message is the same message used by MICOM relays.
10.2 Profibus Interface

Summary of I/O Definitions Required for LVSG Profibus Profile Compliance
Gemstart is covered by two of the profiles described in Profibus Profile for Low
Voltage Switchgear. The two relevant profiles are for Motor Starter and Motor
Management Starter.
- 75 -
Gemstart 5
Gemstart 5 will support all the profiles for Motor Management Starter. Motor Starter
will NOT be covered. Motor Starters are too similar but not compatible with Motor
Management starters and inclusion of both will cause confusion.
The Motor Management starter will be expanded to offer more data by using the
Gemstart profiles.
A reference document for PLC engineers (Profibus Cyclic & Acyclic Data.pdf) is
available on request. This document covers the Cyclic and Acyclic methods of
accessing data in Gemstart via the Profibus protocol.
10.2.1
Motor Management Starter

Motor Management Starter - Monitoring Information
Monitoring Information is defined to be Inputs from the Device to the Host

Controller.
The document describes three formats of monitoring information, each now
considered within its own section.
Motor Management Starter Monitoring Definitions
Profibus
Term
Gemstart Term
Definition
Run Reverse
Running B
Motor is running in reverse or high speed.
Off
Stopped
Motor is not running.
Run Forward
Running A
Motor is running in forward or low speed.
Overload
Warning
Overload
Warning
Set if an overload warning is active.
Lock out time
Restart Inhibit
Set if restart inhibit is active. This feature prevents a start until

there is enough thermal content available to start the motor.
Auto Mode
Auto Mode
Gemstart in serial link mode (Auto or Priority).
Fault
Trip
There is a LTrip (latched trip) or Trip (self clearing trip)

present.
Warning
Warning/Alarm
There is a Warning (self clearing indication) or Alarm (latched

indication) present.
Motor Current Highest Phase

high
The highest phase current as %FLC/32. E.g. a value of 6

means 192%FLC.
Motor Current Lowest Phase

low
The lowest phase current as %FLC/32. E.g. a value of 2

means 64%FLC.
Local Control
Manual Control
The motor is under control of manual start and stop inputs

local to the motor.
Ramping
Startup
The motor current is still above 100%FLC after a start.
- 76 -
Gemstart 5
Motor Management Starter Monitor - Format 0
Transmitted as 4 bytes.
Byte
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Warning
Fault
(Trip)
Lock Out
Time
O/load
Warning
Run
Forward
Off
(or Alarm)
Auto
Mode
Run
Reverse
Status Bit 2
Status Bit 1
Open
Required
Test
Position
Reserved
Reserved
Ramping
Local
Control
Motor Current High (%FLC/32)
Ramping
Local
Control
Motor Current Low (%FLC/32)
(Stopped)
Reserved
Reserved
Motor Management Starter - Command Information

Motor Management Starter Command Definitions
Profibus
Term
Gemstart Term
Definition
Run Reverse
Start B
Request run in reverse or high speed. Removing the signal

does not stop the motor.
Off
Stop
Stop the motor. Run forward and Run Reverse are ignored.
Run Forward
Start A
Request to run forward or low speed. Removing the signal

does not stop the motor.
Self Test
No equivalent function. Gemstart runs self test all the time.
Emergency
Start
Emergency
Start A
Override protection trips to enable Run Forward.
Auto Mode
Priority Mode
Prevent manual mode operation.
Trip Reset
Supervisor
Reset
Reset faults. The faults reset can be configured.
Motor Management Starter Command - Format 0

Received as 2 eight bit bytes.
Byte
0
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Reserved
Trip Reset
Auto
Mode
Emergency
Self Test
Run
Forward
Off
Run
Reverse
Operator
Reset
Reset
kWh
(Supervisor)
GP Output
B
GP Output
A
Start A
Motor Management Starter Command - Format 1

Received as 4 eight bit bytes.
- 77 -
(Not used)
Reserved
Reserved
(Stop)
Reserved
Reserved
Gemstart 5
Byte
0
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Reserved
Trip Reset
Auto
Mode
Emergency
Self Test
Run
Forward
Off
Run
Reverse
Operator
Reset
Reset
kWh
(Supervisor)
GP Output
B
GP Output
A
start
(Not used)
Reserved
(Stop)
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Analogue Output
Reserved
10.2.2
Reserved
Reserved
Reserved
Reserved
Motor Management Starter Supported Profiles
The profiles describe the supported combinations of monitoring and command

formats.
Profile Type
Monitoring Format
Command Format
10.2.3
Gemstart 5 Profile
Input Data - Monitor

Received as 1, 2, 3, 4, or 6 bytes. The six bytes may be followed by 2, 8 or 14 words.
The definition of the first 4 bytes is the same as the Motor Management Starter.
Bytes
Description
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Warning
Fault
Lock Out
(Trip)
O/load
Warning
Run
Forward
Off
(or Alarm)
Auto
Mode
Run
Reverse
Status Bit 2
Status Bit 1
Open
Required
Test
Position
Reserved
Reserved
Ramping
Local
Control
Motor Current High (%FLC/32)
Ramping
Local
Control
Motor Current Low (%FLC/32)
Bits 0,1: Fault Code severity.
(Restart
Inhibit)
Bit 2: GEMPRO in or requesting Control

Bit 3: Motor Available to Host
Bit 4: Motor Available to Priority
Bit 5: In Manual Mode
Bit 6 : Current Value multiplied by 100 (word 12 of this table)
Bit 7 : Power Value multiplied by 100 (word 14 of this table)
- 78 -
(Stopped)
Reserved
Reserved
Gemstart 5
5
Fault Code
(seconds since 1901) MMSB
7
8
9
(seconds since 1901) MSB

Default code change
date/hour
(NTP format)
(seconds since 1901) LSB

(seconds since 1901) LLSB
10
(fraction of a second) MSB
11
(fraction of a second) LSB
12
Amps. 0-65,535 A
14
Power. 0-65,535 kW
16
First Group Number
18
First Group Word 1
20
First Group Word 2
22
First Group Word 3
24
First Group Word 4
26
First Group Word 5
28
Second Group Number
30
Second Group Word 1
32
Second Group Word 2
34
Second Group Word 3
36
Second Group Word 4
38
Second Group Word 5
40
Groupe 13 number (13)
42
Groupe 13 Word 1 (value for trending curve 1)
44
46
48
50
This table gives the details of the greatest possible profile. See after to have different
profiles. Please note that Group13 is used for the Engineering Working Station
Gemview5. For more information about EWS please contact us.
Output Data Command
Transmitted as 1, 2, 3, 4, 5 or 6 bytes.
The definition of the first 4 bytes is the same as the Motor Management Starter.
Byte
0
1
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
Reserved
Trip Reset
Auto Mode
Emergency
Self Test
Run
Forward
Off
Run
Reverse
GP Output
(Supervisor)
(Priority)
GP Output
Operator
- 79 -
start
Reset
(Not Used)
Reserved
Reserved
(Stop)
Reserved
Reserved
Gemstart 5
B
Reset
kWh
Analogue Output
Reserved
First Group Request
Second Group Request
10.2.4
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Profile Data Structure Sizes
The following table shows the sizes of the transferred data blocks in the case of each
of the supported profiles.
Command type
Command
size
Monitoring
size
Manager Starter 1
2 bytes
4 bytes
MS (Manager Starter)
Manager Starter 2
4 bytes
4 bytes
MS
GS5 Profile 1bo, 1bi
1 byte
1 byte
MS (1 byte only)
1 byte
2 bytes
MS (2 bytes)
1 byte
3 bytes
MS (3 bytes)
1 byte
4 bytes
MS
1 byte
6 bytes
MS + default
GS5 Profile 1bo, 6bi + 1wi
1 byte
6 bytes + 1
word
MS + default + current
1 byte
6 bytes + 2
words
MS + default + current + power
2 bytes
1 byte
MS (1 byte only)
2 bytes
2 bytes
MS (2 bytes)
2 bytes
3 bytes
MS (3 bytes)
2 bytes
4 bytes
MS
2 bytes
6 bytes
MS + default
2 byte
6 bytes + 1
word
2 bytes
6 bytes + 2
words
3 bytes
1 byte
MS (1 byte only)
3 bytes
2 bytes
MS (2 bytes)
3 bytes
3 bytes
MS (3 bytes)
3 bytes
4 bytes
MS
3 bytes
6 bytes
MS + default
3 byte
6 bytes + 1
word
- 80 -
Profile details (monitored values)
st
st
st
Gemstart 5
Command type
Command
size
Monitoring
size
3 bytes
6 bytes + 2
words
4 bytes
1 byte
MS (1 byte only)
4 bytes
2 bytes
MS (2 bytes)
4 bytes
3 bytes
MS (3 bytes)
4 bytes
4 bytes
MS
4 bytes
6 bytes
MS + default
4 byte
6 bytes + 1
word
4 bytes
6 bytes + 2
words
4 bytes
14 bytes +
8 words
MS + dfaut + courant + puissance +

groupe 13
4 bytes
12 bytes +
2 words
MS + default + NTP + current + power
4 bytes
12 bytes +
8 words
MS + default + NTP + current + power +

group 13
5 bytes
6 bytes + 8
words
MS + default + current + power + 1 data

group
5 bytes
6 bytes +
14 words

group + group 13
5 bytes
12 bytes +
14 words

1 data group + group 13
6 bytes
6 bytes +
14 words

groups
GS5 Profile 6bo, 6bi + 14wi + 6wi
6 bytes
6 bytes +
14 words +
6 words

group + group 13
GS5 Profile 6bo, 12bi + 14wi +

6wi
6 bytes
12 bytes +
14 words +
6 words

2 data group + group 13
10.2.5
Profile details (monitored values)
st
Group Data
It is possible for the Profibus Master to issue one or two requests for specific groups
of data from a specific Gemstart. Gemstart offers 10 different data groups. All values
are Unsigned 16 bit numbers unless indicated otherwise.
Group 1 - Current and Power Percentage
Field
Description
ALC Current (%ALC)
Highest phase current as % of ALC
FLC Current (%FLC)
Highest phase current as % of FLC
- 81 -
Gemstart 5
Field
Description
Earth
Fault
(%EFC)
Current Earth Fault current as a percentage of trip level
Power (%Rating)
Average power as % of the configured rated

power
Power Factor
(0-100). Divide by 100 to get the power factor
Group 2 - Link Info / Input Counter 1

Field
Description
Link Timeouts
Number of Timeouts detected by Gemstart since

counter last reset
CRC Errors
Number of CRC Errors detected by Gemstart

since counter last reset
Input Counter
(Thousands)
Input counter 1 divided by 1000.
Input Counter 1 (Units)
(0-999) The remainder of input counter 1 divided

by 1000
Spare
For future use
Group 3 - Contactor Info 1

Field
Description
Hours Run (Hrs)
The number of complete hours that the contactor

has been closed
Operations
(Hundreds)
Operations
(Units)
of
of
A The number of operations of contactor A divided by

100.
A
(0-99) The remainder of the number of operations

of contactor A divided by 100.
Starts in last hour
(0 to 255) Number of starts during the last hour
Spare
For future use
Group 4 - Contactor Info 2 / Supply Voltage

Field
Operations
(Hundreds)
Description
of
B The number of operations of contactor B divided

by 100.
Operations of B (Units)
Operations
(Hundreds)
of

of contactor B divided by 100.
C The number of operations of contactor C divided

by 100.
Operations of C (Units)
- 82 -

of contactor C divided by 100.
Gemstart 5
Field
Motor Supply
(%Nominal)
Description
Voltage The motor supply voltage as a percentage of
nominal supply voltage
Group 5 - Input Counters 2 and 3

Field
Description
Input Counter
(Thousands)

Input Counter
(Thousands)
(0-999) The remainder of input counter 2

divided by 1000
(0-999) The remainder of input counter 3

divided by 1000
Hardware I/O
The state of Gemstart5s input and output pins

Bit 0 = Interlock, Bits 1 to 9 = Inputs 1 to 9
Bits 12 to 15 = Outputs 1 to 4
Group 6 - Current and Power (units)

Field
Description
Highest Phase Current Highest phase current. Divide by Highest Current

(Scaled Amps)
Divider (Group 6, Word 2) to get Amps. See
Note 1 at the end of the table.
Highest Current Divider
Adjust Highest Current (Group 6, Word 1) to put

the decimal point in the correct place. (Values are
1, 10, 100, 1 000, 10 000) See Note 1 at the end
of the table.
Power (Scaled kW)
Real Power. Divide by Power Divider (Group 7,

Word 5) to get kWatts. See Note 1 at the end of
the table.
Earth
Fault
(Scaled Amps)
Current Earth Fault Current. Divide by Earth Fault

Divider (Group 6, Word 5) to get Amps. See
Note 1 at the end of the table.
Earth Fault Divider
Adjust Earth Fault Current (Group 6, Word 4) to

put the decimal point in the correct place. (Values
are 1, 10, 100, 1 000, 10 000). See Note 1 at the
end of the table.
Group 7 - Startup
Field
Description
Startup Time (s)
Number of seconds for the last successful startup

(Note: A successful start is one with no trip or
stop before the current drops below 100%FLC)
- 83 -
Gemstart 5
Field
Peak Startup
(%FLC)
Description
Current Maximum current achieved during last successful
startup as a percentage of FLC. (Note: A
successful start is one with no trip or stop before
the current drops below 100%FLC)
Auto Restart Timer (1s Time in seconds before the motor is restarted
units)
Imbalance (%)
The imbalance current (highest minus lowest)

either as a percentage of the highest phase
during startup or as a percentage of FLC after
startup.
Power Divider
Adjust kW Power (Group 6, Word 3) to put the

decimal point in the correct place. (Values are 1,
10, 100, 1 000, 10 000). See Note 1 at the end of
the table.
Group 8 - Thermal and kWh meter

Field
Description
Thermal Content used by Estimation of heat energy used during last start
start (%)
as a percentage of the fault level
Thermal Content (%)
Estimation of heat energy in the motor as a

percentage of the maximum level
Time to Trip / Available The number of seconds before Gemstart will trip
(s)
or become available
kW hour meter (kWh)
kWh hours measured since kWh was last reset

(0-9999)
MW hour meter (MWh)
MWh hours measured since kWh was last reset

(0-9999)
Group 9 - Trip Counters

Field
Description
Thermal Trip Counter
Number of thermal trips since counter last

reset
Imbalance Trip Counter
Number of imbalance trips since counter last

reset
Earth Trip Counter
Number of earth fault trips since counter last

reset
Other Protection
Counter
Trip Number of other protection trips since counter

last reset
Reactive Power
Reactive Power. Divide by Power Divider

(Group 7, Word 5) to get kVAR
- 84 -
Gemstart 5
Group 10 - Configurable
Field
Description
Data
Word
Any one of the previous data words, as

configured
Data
Word

configured
Data
Word

configured
Data
Word

configured
Data
Word

configured
Field
Description
RTD measurement
RTD1 (MSB) & RTD2(LSB)
RTD measurement
RTD measurement
RTD measurement
RTD Group1 (MSB) & RTD Group2 (LSB)
RTD Status
see chapter 6.3.12.4
Group 11 - RTD
Group 12 Individual currents

Field
Description
Current Phase 1
Phase 1 current in Amps
Current Phase 2
Phase 2 current in Amps
Current Phase 3
Phase 3 current in amps
Spare
For future use
Spare
For future use
NOTE: The data items, Highest Phase Current (Amps), Earth Fault Current
(Amps) and Real Power (kW), are scaled to keep a reasonable amount of
detail in the readings. The scaling values are defined by the configuration
and do not change dynamically.
The following table may help you understand how the data is related.
CT Current (adjusted GS Display
for Turns)
Current Divider Current

Group6: Word 2 Group 6: Word 1
0.010A-0.099A
0.1234 A
10000
1234 = 0.1234A
0.10A-0.99A
1.234 A
1000
1234 = 1.234A
- 85 -
Gemstart 5
1.0A-9.9A
12.34 A
100
1234 = 12.34A
10A-99A
123.4 A
10
1234 = 123.4A
100A-990A
1234 A
1234 = 1234A
1.0k - 9.9k
12.34 kA
12340 = 12340A
10k
23.4 kA
23400 = 23400A
- 86 -
Gemstart 5
Rated Power
GS Display
Power
Divider Power
Group7: Word 5
Group 6: Word 3
0.10kW-0.99kW
1.234 kW
1000
1234 = 1.234 kW
1.0kW-9.9kW
12.34 kW
100
1234 = 12.34 kW
10kW -99kW
123.4 kW
10
1234 = 123.4 kW
100kW -990kW
1234 kW
1234 = 1234 kW
1.0MW - 9.9MW
12.34 MW
12340 = 12340 kW
10MW
23.4 MW
23400 = 23400 kW
10.3 Gembus Interface

This section describes Gemstart when running with a Gembus Host. At present this
is limited to the GE FANUC PCM driver.
A serial link connection is provided for you on each Gemstart to allow a Host to
remotely control and interrogate it for performance data. Gemstart 5 with Gembus
communicates over a 4-wire, full duplex RS485 link using a proprietary protocol
which maintains backward compatibility. The link can also be used to access the
configuration of Gemstart 5. Each link can support one hundred units.
A Gembus Host holds a copy of the configuration of each Gemstart connected. The
configuration in the Host is automatically checked and updated every time the serial
link is established.
10.3.1
Configuration of the Serial Link
There are some aspects of the Gembus serial link that can be configured for each
Protocol
Select Gembus. (Note if the link address is > 99 then Gembus will not be
offered).The Modbus and Profibus options are discussed elsewhere.
Link Fail Action (Communications/Link Fail Action)
Trip:
Open the Contactor and report a Link Trip message;
Warn:
Leave the Contactor unchanged and report a Link Warn message;
Off:
No action. Leave the Contactor unchanged. No Link fault reported.
Configurable Host status bits(Communications/s/Status Bit Source)

Two bits are available in the status word, which may be separately configured to any
of the inputs of Gemstart 5. The available options for these bits are Disabled, Active,
INTERLOCK INPUT, and INPUTS 1 -12, OUTPUT 4.
Group 10 (Communications/Group 10 Word x)
- 87 -
Gemstart 5
A configurable data group has been provided. This allows the user to select items
from the 10 fixed groups to be sent as one group 10 message. See the section, Data
Groups, where the available options are covered.
Control Group (Communications/Control Group)
Define which Control Group this Gemstart is a member of. Options of Off and groups
1 to 7 are available. The Gembus Host can send a Group Control command to
control several Gemstarts at the same time. This command contains a standard 4 bit
contactor control command and 7 Group Flags. If the Group Flag corresponding to
this Gemstarts group is set, then Gemstart will use the 4 bit group command as the
serial link command and ignore the normal serial link command. When the relevant
Group Flag is cleared Gemstart will revert to using the normal serial link command.
The Command display under the LINK status key will show (Grp) when a Group
Command is being used.
Link Number and Address (Communications/Advanced Settings/Address)
This value identifies a specific Gemstart on the Link. It can only be altered using the
GEMPRO control program to change it from Not Set to the desired address. Once
the address is set only COMECA engineers can change the address. This protects
the address from accidental changes. Links can be numbered 0 to 15. Each link can
support one hundred units. Valid address values are 0 to 99.
Fixed Baud Rate(Communications/Advanced Settings/Baud Rate)
You can connect Gemstart to links running at 600, 1200, 2400, 4800, 9600, 19200 &
115 200 baud. Gemstart can auto search for the baud rate of the link to which it is
connected or can be configured to always run at one of the three fastest rates. Fixing
the baud rate means that time is not wasted searching for messages at the incorrect
rate.
Fixed Timeout (Communications/Advanced Settings/Fixed Timeout)
The serial link Fixed Timeout time defaults to Auto. The Auto option has a different
timeout time for each baud rate as follows:
115200
2.5s
19200 & 9600,
2.5s
4800
5s
2400
10s
1200 & 600
20s
The Fixed Timeout configuration also allows fixed timeouts of 5s, 10s and 20s. These
options fix the timeout regardless of the baud rate. The timeout time is the time
between valid messages to any address seen on the link. It is NOT related to the link
scan time.
10.3.2
Serial Link Commands
The command sent to Gemstart consists of 2 bytes. These bytes are:

Contactor Command Byte
Resets and GP Outputs Byte
Gemstart 5 is capable of receiving broadcast commands from the Host. The
broadcast commands are transmitted by the Host as soon as it detects a new start or
stop command. The broadcast command allows starts and stops to be quickly
passed to every Gemstart without having to wait for the Gemstart scan to reach the
desired address.
- 88 -
Gemstart 5
Contactor Command
Table 6.
Table 6 Gembus contactor command codes
Bits 3-0
Command
Mode
0000
Stop
Auto
0001
Close A
Auto
0010
Close B
Auto
0011
No Action
Auto
0100
Priority Open
Priority
0101
Reserved for Gemstart 3 functionality
Auto
0110
Auto
0111
For future expansion
Auto
1000
Stop
Priority
1001
Close A
Priority
1010
Close B
Priority
1011
No Action
Priority
1100
Priority Open
Priority
1101
For future expansion Reserved for Gemstart 3 Priority

functionality
1110
Priority
1111
Priority
example Forward/Reverse, Low/High Speed, Close/Open Value).
When Gemstart is operating as a GP I/O device, bits 3 to 0 are the requested states
for outputs D, C, B, A respectively. There is no priority mode on a GP I/O device.
appears. If a close command is present and the contactor is not closed then an
Open Required Fault is reported by Gemstart. This fault can be cleared by sending
an open command until the fault clears then send the close command again.
Alternatively close the contactor with the GEMPRO control program.
Resets and I/O functions byte
Six bits of this field are relevant to you. These six bits include four GP Output bits and
two reset bits.
Table 7 - Reset and General Purpose Outputs Byte
Bit
Command
General Purpose Output A
- 89 -
Gemstart 5
Bit
Command
General Purpose Output B
General Purpose Output C
General Purpose Output D
Operator Reset
Supervisor Reset
Any spare outputs can be configured (Fuses And Contactors) to output the GP O/P
bits received from the host.
The function of the Reset from Host Supervisor and Reset from Host Operator bits
depends on configuration (see Communications/Host Resets). A range of individual
resets can be assigned to each of these bits, as given below:
Reset All
All reset functions as defined below
Thermal overload
Reset overload faults without resetting other

motor protection faults
Motor Protection(inc. O/L)
Start Time, Start Level, Thermal Overload,

Ops per hour etc.
All ALC based protection & phase reversal
Interlocks
Failed to close, Unexpected open, and User

defined text faults
Alarms
All alarms
Earth
Earth fault and ELCB Relay
As a default the Host operator will be allowed to reset :

Alarms, Overloads and Application protection
As a default the Host Supervisor will be allowed to reset:
Alarms, Overloads, Motor protection and Application protection
10.3.3
Data Available from Gemstart 5
Status Message
A Gembus Host allows you to define the length of the Status message Gemstart
sends on every scan. The more data sent in the status message by each Gemstart
the longer the scan time. Although on some systems the increase may only be
marginal. The options are:
Message Types
Contents
Short Status Message Status Word

Standard
Message
Status Status Word Display Value
Long Status Message
Status
Word
Fault Code
- 90 -
Display
Value
Gemstart 5
Message Types
Contents
Group 10 Status
Status Word Display Value Fault

Code
Group
10
Word
1
Group
10
Word
2
Group
10
Word
3
Group
10
Word
4
Group 10 Word 5
Status Word
The following status word is provided in every response to the Host.
Table 8 - Gembus Status Word
Bit
Gemstart Controlling a Contactor
Set by Host if Gemstart not responding
Set if Any Trip active (latching or self clearing) (Same as Trip LED)
Set
if
(Same as Alarm LED)
Any
Alarm
is
active
Set
if
(Same as Warn LED)
Any
Warn
is
active
Set if a Latching Trip is Active
Contactor A State
Contactor B State
10
Set if motor Stopped (Contactors open and current < 16%)
11
Configurable
defaults to Disabled
12
Set if in, or requesting, Manual mode.
13
Configurable
defaults to Disabled
14
GEMPRO is in, or Requesting, Control
15
Set if motor available to Host (i.e. no trips, and in auto or priority modes,
and not in test position)
Host
Host
Status
Bit
1,
Status
Bit
2,
Display Value
This is the value which is displayed on the Gemstart LCD. The value does not
include the decimal point. So if Gemstart is displaying 12.34A then value 1234 is
passed on the link.
Fault Code
The Fault Code is represented by two bytes. The least significant byte holds a code
- 91 -
Gemstart 5
defining what the fault is. The most significant byte holds a code for the severity of
the fault (0=warn, 1=alarm, 2=trip, 3=latching trip).
Group 10 Data
The group data items. As configured in Communications section of the Configuration
Editor, Group 10 Word sources.
10.3.4
Group Data
It is possible for the Host to issue a request for a specific group of data from a
specific Gemstart. Gemstart offers 11 different data groups. Each group data
message includes the Long Status Message described above.
If the Group 10 Status message is active, a request for a specific group message will
cause the correct group message to be sent, for 1 scan, in place of the group 10
status message.
Gemstart provides you with data groups 1 to 11. All values are Unsigned 16 bit
numbers unless indicated otherwise.
See section 10.2.5 in the Profibus section for a definition of the Group Data contents.
10.3.5
Serial Link Timeout Operation
If no valid messages are received by Gemstart from the Host system within the
timeout period, a Link Fail Trip or Warn is flagged.
Once the link is established the timeout period of each baud rate on the link is:
Baud Rate:
19200
9600
4800
2400
1200
600
Seconds:
2.5
2.5
10
20
20
The baud rate can be forced for any baud rate to be 5, 10 or 20s. See configuration
item Communications/s/Advanced Settings/Fixed Timeout
The auto detect method for Baud (and protocol) selection is as follows:
Gemstart will only try a new baud rate if it is receiving bytes but has not received a
valid message for 1.5s
The 1.5s time starts when the first byte has been received after a timeout. When an
active link times out the baud rate is not changed .
The normal order of events is as follows:
1.
A healthy link stops transmitting
2.
After the timeout time associated with the baud rate, the link fail action will
occur (trip or warn). The baud rate will not change. No further timeouts are possible
until a byte has been received
3.
The first byte received will start the 1.5s timer
4.
If a valid message is received within 1.5s then the link is re-established
5.
If a valid message is not received, a timeout is recorded and the baud rate is
changed. The mechanism then goes back to step 3
If data is being continuously transmitted by the Host the unit will spend 1.5s at each
baud rate until it receives a valid message.
- 92 -
Gemstart 5
10.3.6
Serial Link Performance Statistics
Gemstart provides you with the following serial link statistics which can be viewed on
the GEMPRO control program:
10.3.7
Link Status
Indicates and serial link faults or the present link operation if

there are no faults.
Baud rate
The speed the serial link is operating at.
Address
Range
The lowest and highest address detected on the link.
Scan Time
The time taken to communicate with every unit on the link.
Link Timeouts
The number of times an expected message to this Gemstart

was not received. Also available in Link Info data group
CRC Errors
Number of messages which should have been sent to this

Gemstart but were not received due to corruption. Also
available in Link Info data group
PCM Version
Displays the software version of the Gembus driver in the

GE FANUC PCM
Broadcasts
Counts the number of broadcast messages received.

Includes Fast Command messages sent when a contactor
command changes and Group Control messages.
Command
The serial link command that is being used. This is usually

the command sent out during the Gembus scan. If this
command is over-ridden by a Group Command the display
will show (Grp).
Serial Link Compatibility
Gemstart is compatible with all previous versions of the Gembus Hosts.

The compatibility of Gemstart versions with the various Host formats is described by
the following table. With the exception of Gemstart 1 Hosts, all combinations work
but may have restricted functionality.
Table 9 - Gemstart compatibility
Host
Gemstart 1
Gembus 1 Host
Gemstart 1 is Cannot
use
fully functional
Gemstart 2 on this
Host due to the
extended
Set
Configuration
message
GEM80 IOP mode 6

or
FAST I/O 8331-4001
Gembus 2 Host
GEM80 IOP mode 8
or
FAST I/O 8331-4002
Gemstart 2
Gemstart 3
Gemstart 4/5
Cannot
use
Gemstart 3 on
this Host due to
the
extended
Set
Configuration
message
Cannot
use
Gemstart on this
Host due to the
extended
Set
Configuration
message
Gemstart 1 is Gemstart 2 is fully Static

Data Static
Data
fully functional
functional
Message
Message
supported
supported
Configuration
not available via
link
- 93 -
Gemstart 5
Host
Gembus
Hosts
ICIS Version 2.x
GE Fanuc PLC
PCM
Gembus
driver
X-Link
Gemstart 1
Gemstart 2
Gemstart 3
Gemstart 4/5
3 Gemstart 1 is Gemstart 2 is fully Gemstart 3 is Gemstart

fully
fully functional.
functional.
fully functional.
emulates
Gemstart
3
Static data is Static data is sent Short
status
when on link 0
sent in reply to in reply to data messages
are
with
and
sends
data
group group requests.
only supported
v2
Gemstart
3
requests.
by later releases
Short
status
groups.
of Gemstart 3
Short
status messages are not
firmware
Configuration
messages
are supported
not available via
not supported
link
Gembus Host
As above
GE Fanuc PLC with

PCM Gembus v3.xx
driver
Group
10
Status
Message
supported
from version v3.41
As above
Gemstart Hosts
deal
with
Group 10 Status Group 10 Status
Gemstart
3s
message is not message is not
correctly. Only
supported
supported
later releases of
Gemstart
3
support
short
status message
Gemstart is fully
functional
Group 10 Status
message
supported from
version F1.
Group 10 Status
message is not
supported
Gemstart cannot be used with a Gemstart 3 Host set to Host Read Only.
If operating on a Gemstart 3 Host, the messages returned by Gemstart to the Host
are identical to those returned from Gemstart 3, refer to Table 11and Table 12.
10.3.8
Serial Link Cabling
The cable used for the four-wire serial link should consist of two twisted pairs with an
overall screen, have a maximum capacitance of 180nF/km, and a maximum
resistance of 40 ohms/km. When routing the cables and wiring outside the cubicles
you should ensure that there is a minimum distance of 600mm (2 feet) exists
between the serial link cabling and any electrically dirty wiring. The recommended
cable type is: Belden 9729.
When connecting Gemstart to a Westermo unit the connections go as follows:
Westermo Tx+ connects to Gemstart RxWestermo Tx- connects to Gemstart Rx+
Westermo Rx+ connects to Gemstart TxWestermo Rx- connects to Gemstart Tx+
10.3.9
Termination of Serial Links
You must correctly terminate the serial link for communications to be successful. You
achieve correct termination by fitting a 220 ohm, 0.25W resistor across each pair of
Tx and Rx wires on Gemstart located at each end of the serial link.
- 94 -
Gemstart 5
10.4 Gembus 3 Interface

This section describes Gemstart when running with any previous version of the
Gembus Host.
Gemstart can be used on extensions to Gemstart 2 and Gemstart 3 links. The
additional features of Gemstart cannot be made available but Gemstart will provide
the same information in the same format as Gemstart 3.
Gemstart cannot be configured via a Gembus 3 serial link.
10.4.1
Configuration for Gembus 3
There are some aspects of the Gembus 3 serial link that can be configured for each
Protocol
Select Gembus . The Modbus options is discussed elsewhere.
Link Fail Action(Communications/Link Fail Action)
Trip:
Open the Contactor and report a Link Trip

message;
Warn:
Leave the Contactor unchanged and report a

Link Warn message;
Off:
No action. Leave the Contactor unchanged. No

Link fault reported.
Configurable Host status bits(Communications/Status Bit Source)

These bits have no relevance to a Gembus 3 link.
Group 10 (Communications/s/Group 10 Word x)
This has no relevance to a Gembus 3 link.
Link Number and Address (Communications/ Settings/Address)
This value identifies a specific Gemstart on the Link. It can only be altered using the
GEMPRO control program to change it from Not Set to the desired address. Once
the address is set only COMECA engineers can change the address. This protects
the address from accidental changes. For Gembus 3 the link must be set to 0. Valid
address values are 000 to 099.
Fixed Baud Rate(Communications/Baud Rate)
You can connect Gemstart to links running at 600, 1200, 2400, 4800, 9600, and
19200 baud. Gemstart can auto search for the baud rate of the link to which it is
connected or can be configured to always run at one of the three fastest rates. Fixing
the baud rate means that time is not wasted searching for messages at the incorrect
rate.
Fixed Timeout (Communications/Fixed Timeout)
The serial link Fixed Timeout time defaults to Auto. The Auto option has a different
timeout time for each baud rate as follows:
19200 & 9600,
4800
2.5s
5s
- 95 -
Gemstart 5
2400
1200 & 600
10s
20s
The Fixed Timeout configuration also allows fixed timeouts of 5s, 10s and 20s. These
options fix the timeout regardless of the baud rate. The timeout time is the time
between valid messages to any address seen on the link. It is NOT related to the link
scan time.
10.4.2
Gembus 3 Commands
Table 10:
Table 10 Gembus 3 contactor command codes
Bits 3-0
Command
Mode
0000
Stop
Auto
0001
Close A
Auto
0010
Close B
Auto
0011
No Action
Auto
0100
Stop
Priority
0101
Host Operator Reset
Auto
0110
Host Supervisor Reset
Auto
0111
Auto
1000
Stop
Priority
1001
Close A
Priority
1010
Close B
Priority
1011
No Action
Priority
1100
Stop
Priority
1101
Host Operator Reset
Priority
1110
Host Supervisor Reset
Priority
1111
Priority
example Forward/Reverse, Low/High Speed, Close/Open Value).
When Gemstart is operating as a GP I/O device, bits 3 to 0 are the requested states
for outputs D, C, B, A respectively. There is no priority mode on a GP I/O device.
appears. If a close command is present and the contactor is not closed then an
Open Required Fault is reported by Gemstart. This fault can be cleared by sending
an open command until the fault clears then send the close command again.
Alternatively close the contactor with the GEMPRO control program.
- 96 -
Gemstart 5
10.4.3
Data available from Gemstart 5
Status Message
Some Gembus 3 Host allows you to define the length of the Status message
Gemstart sends on every scan. The more data sent in the status message by each
Gemstart the longer the scan time. Although on some systems the increase may only
be marginal. The options are:
Message Types
Contents
Short Status Message Gemstart

Word
Status
Standard
Message
Status
Status Gemstart
Word
Gemstart
Value
Load
Gemstart 3 Status Word

The following status word is provided in every response to the Host.
Table 11 - Gemstart 3 Mode Status Word
10.4.4
Bits
Description
0-5
Gemstart 3 Fault Code
Set if GEMPRO control program is requesting control
Set if Gemstart is in the Test Position
Set if Contactor A is closed
Set if contactor B is closed
10
Set if the Isolator is Closed
11
Low if manual stop is active
12
Configurable Status Bit 11 (See COMMUNICATIONS/S). Set to input 4

to get equivalent function of Gemstart 2s input 1.
13
Configurable Status Bit 13 (See COMMUNICATIONS/S). Set to input 7

to get equivalent function of Gemstart 2s input 2.
14
Set if Gemstart is in Local Control
15
Set if Gemstart can be operated in the present mode (AVAILABLE)
Gemstart 3 Fault Codes
The following tables indicate the fault codes generated by Gemstart 5 when
communicating with a Gemstart 2 or Gemstart 3 Host. The tables show the fault
codes that are generated for each of the 3 severity levels. (Gemstart allows the
severity of most faults to be configured.) The first figure is the code generated when
a fault is defined as a LTrip (Latched Trip) or a self clearing Trip. The second code is
for an Alarm and the third for a Warn. e.g. A Thermal Overload Trip will generate a
fault code of 8. A Thermal Overload Warn will generate a code of 51.
- 97 -
Gemstart 5
FAULT CODE
GEMSTART FAULT
COMMENT
(L)Trip, Alarm, Warn

00
No faults present
01
Gemstart Not responding
02, 02, 02
Configuration Conflict
03, 03, 03
Isolator Fault
04, 04, 04
Undefined Fault
05, 05, 63
Earth Fault
06, 06, 06
Thermistor Relay Fault
07, 07, 63
Single Phasing Fault
08, 08, 51
Thermal Overload Fault
09, 09, 36
User Text 1 Fault
10, 10, 37
User Text 2 Fault
11, 11, 11
Manual Stop
Pressed
12, 12, 12
Interlock fault
13, 13, 13
Failed to Close A fault
14, 14, 14
Failed to Close B fault
15, 15, 15
Failed to Open A fault
16, 16, 16
Failed to Open B fault
17
Generated by Host.
Not
Generated
Gemstart 5
by
Invalid
Contactor
Feedback
A Not
Generated
Gemstart 5
by
18
Invalid
Contactor
Feedback
B Not
Generated
Gemstart 5
by
19, 19, 19
Current
Flow
Detected
While Contactor Open
20, 20, 20
Forward / Reverse conflict
21, 21, 21
Release Host Start
22, 41, 52
Under Current Fault
23, 23, 63
Start Current Fault
24, 42, 53
Start Time Fault
25, 43, 54
Continuous ALC Fault
26, 44, 55
Instant ALC Fault
27, 27, 27
Restart Inhibit
28, 28, 28
Supply Fail
29, 29, 29
ELCB Fault
- 98 -
or
STOP
Gemstart 5
FAULT CODE
GEMSTART FAULT
COMMENT

30, 30, 30
Overload Relay Fault
31, 38, 48
Imbalance Fault
32
Yellow
trip
33
Blue Phase Imbalance trip
34, 45, 63
Power Factor High

Power Factor Low fault
35, 35, 35
Overload Reset Delay
09, 09, 36
User Text 1 Fault
10, 10, 37
User Text 2 Fault
31, 38, 48
Imbalance Fault
39
Yellow
alarm
40
Blue
alarm
22, 41, 52
Under Current Fault
24, 42, 53
Start Time Fault
25, 43, 54
26, 44, 55
Instant ALC Fault
34, 45, 63
Power Factor High

Power Factor Low fault
46
Under Voltage Warn
Not
Generated
Gemstart 5
by
47
Over Voltage Warn
Not
Generated
Gemstart 5
by
31, 38, 48
Imbalance Fault
49
Yellow
warn
Imbalance Not
Generated
Gemstart 5
by
50
Blue Phase Imbalance warn Not

Generated
Gemstart 5
by
08, 08, 51
Thermal Overload Fault
22, 41, 52
Under Current Fault
24, 42, 53
Start Time Fault
25, 43, 54
26, 44, 55
Instant ALC Fault
- 99 -
Phase
Phase
Phase
Phase
Imbalance Not
Generated
Gemstart 5
by
Not
Generated
Gemstart 5
by
Imbalance Not
Generated
Gemstart 5
by
Imbalance Not
Generated
Gemstart 5
by
or
or
Gemstart 5
FAULT CODE
GEMSTART FAULT
COMMENT

56, 56, 56
AutoRestart Count Down

Active
57, 57, 57
Release Manual Start Fault
58, 58, 58
PAMM Read/Write Fault
59
Not Defined
Not
Generated
Gemstart 5
by
60
Not Defined
Not
Generated
Gemstart 5
by
61, 62, 63
Non
Fault
Specific
Gemstart Faults introduced in GS5
Gemstart 3 Load Value

The load value normally contains percentage current. Percentage power is sent if the
Gemstart LCD is configured to display Power. During startup the percentage is
referenced to FLC. After startup the percentage is referenced to ALC.
Table 12 - Gemstart 3 Load Value:
Bits
Description
0-10
11 bit representation of current or power
11
Not used. Set to zero
12
Set if start A input active
13
Set if start B input active
14-15
Encoded as:
0 - Load is current as % ALC

1 - Load is power as %(V.ALC)
2 - Load is current as % FLC
3 - Load is power as %(V.FLC)
10.4.5
Gemstart 3 Group Data
Gemstart 3 Links
If group data is requested from a Gemstart on a Gemstart 3 Host link, Gemstart will
emulate Gemstart 3 and return the groups shown below.
All values are unsigned 16 bit numbers unless indicated otherwise.
Gemstart 3 Group 1
Field
Current
%FLC)
Description
(%ALC, The percentage current of the highest phase. The
percentage is a ratio of FLC during startup and ALC
at all other times.
- 100 -
Gemstart 5
Field
Description
Power (%Rating)
Average power as % of the configured rated power
Gemstart 3 Group 2
Field
Description
Current (%ALC, %FLC)
The percentage current of the highest phase. The

percentage is a ratio of FLC during startup and
ALC at all other times.
Power (%Rating)

power
Time to Trip / Available The number of seconds before Gemstart will trip
(s)
or become available
Earth Fault
(%EFC)
Current Earth Fault current as a percentage of trip level
Thermal Content (%)
Estimation of heat energy in the motor as a

percentage of the maximum level
Power Factor
(0-100). Divide by 100 to get the power factor
Gemstart 3 Group 3
Field
Description
The percentage current of the highest phase.

The percentage is a ratio of FLC during startup
and ALC at all other times.
Power (%Rating)

power
Hours Run (Hrs)
The number of complete hours that the contactor

has been closed
Operations
(Hundreds)
of
A The number of operations of contactor A divided

by 100.
Operations
(Hundreds)
of
B The number of operations of contactor B divided

by 100.
Motor Supply
(%Nominal)
Voltage The motor supply voltage as a percentage of

nominal supply voltage
Gemstart 3 Group 4
Field
Description
The percentage current of the highest phase.

The percentage is a ratio of FLC during startup
and ALC at all other times.
Power (%Rating)

power
- 101 -
Gemstart 5
Field
Description
Startup Time (s)
Number of seconds for the last successful

startup (Note: A successful start is one with no
trip or stop before the current drops below
100%FLC)
Peak Startup
(%FLC)
Current Maximum
current
achieved
during
last
successful startup as a percentage of FLC.
(Note: A successful start is one with no trip or
stop before the current drops below 100%FLC)
Link Timeouts
Number of Timeouts detected by Gemstart since

counter last reset
CRC Errors
Number of CRC Errors detected by Gemstart

since counter last reset
Gemstart 2 Static Data Request

If Static data is requested from a Gemstart (by a Gemstart 2 Host), Gemstart will
return the Static Data message shown in Table 13.
Table 13 - Message returned from a Static data request
Word
Bits
Field
Description
015
Gemstart
Word
015
Gemstart 3 Load Value
See above
015
Hours Run (Hrs)
The number of complete hours that the

contactor has been closed
015
Operations
(Hundreds)
of
A The number of operations of contactor

A divided by 100.
015
Operations
(Hundreds)
of
B The number of operations of contactor

B divided by 100.
0-7
Startup Time (s)
815
Time to Trip / Available The number of seconds before

(s)
Gemstart will trip or become available
015
Peak Startup Current Maximum current achieved during last

(%FLC)
successful startup as a percentage of
FLC. (Note: A successful start is one
with no trip or stop before the current
drops below 100%FLC)
0-7
Earth Fault
(%EFC)
815
Thermal Content (%)
Status See above
Number of seconds for the last

successful startup (Note: A successful
start is one with no trip or stop before
the current drops below 100%FLC)
Current Earth Fault current as a percentage of

trip level
- 102 -
Estimation of heat energy in the motor

as a percentage of the maximum level
Gemstart 5
Word
Bits
Field
Description
0-7
Power Factor
(0-100). Divide by 100 to get the power

factor
815
Motor Supply Voltage The motor supply voltage as a

(%Nominal)
percentage of nominal supply voltage
015
Link Timeouts
Number of Timeouts detected

Gemstart since counter last reset
10
015
CRC Errors
Number of CRC Errors detected by

Gemstart since counter last reset
Bad CRC
This is Modbus Counter 2. Number of messages ignored

due to corruption
Bus
Messages
This is Modbus Counter 1. The total number of valid

messages seen on the link
Events

messages actioned by this unit. This includes broadcast
messages which have been actioned
Broadcasts

messages to address 00 seen on the link
Messages
Me
Exceptions
to This is Modbus Counter 4. The total number of valid

messages addressed to this unit
messages which could not be actioned as the function code
or address or data was invalid
Pressing RESET then LINK while displaying Bus Messages, Event Counter,
Broadcasts, or Slave Messages will reset all 4 statistics.
Pressing RESET then LINK while displaying CRC Errors, Bus Exceptions, or
Timeouts will reset all 3 statistics.
- 103 -
by
Gemstart 5
11 Gemstart 5 Ordering Codes

This defines the type of Gemstart 5 body unit and the power supply rating.
GS51_AC
Gemstart 5.1 - 110V 240V AC & 110V DC
GS51_DC
Gemstart 5.1 - 24 48 V DC
GS53_AC*
GS53_DC*
GS54_AC
GS54_DC
GS51/ESD_AC*
Gemstart 5.1 + ESD SUPPLY - 110V 240V AC & 110V DC
GS51/ESD_DC*
Gemstart 5.1 + ESD SUPPLY - 24 48 V DC
GS53/ESD_AC*
GS53/ESD_DC*
GS54/ESD_AC*
GS54/ESD_DC*
* end of life
Optional display modules:
GS5_LED
LED FRONT PANEL MODULE & RJ45 LEAD
GS5_LCD
LCD FRONT PANEL MODULE & RJ45 LEAD
GS5_GEMPRO
CABLE
GEMPRO PROGRAMMING LEAD FOR CONNECTING TO A

PC
Optional extension modules:

GS5_INPUT
INPUT MODULE & RJ45 LEAD
GS5_RTD
RTD MODULE & RJ45 LEAD
GS5_PAMM
Optional PAMM (Chassis mounted)
External current transformer options:

Phase CTs
GS5_CT2
PRIMARY CURRENT RANGE 25A 160A

BLOCK)
(3 CTS IN 3CT
GS5_CT2a (end PRIMARY CURRENT RANGE 25A 160A

of life)
BLOCK)
(2 CTS IN 3CT
Earth Fault CT
GS5_CBCT
STANDARD CBCT, CURRENT RANGE 4A 160A
- 104 -
Gemstart 5
12 GEMPRO PC Software Tool

Gemstart 5 is provided with COMECAs bespoke Control and Configuration software
program, named GEMPRO, which will be supplied to the User under freeware
license. It runs on standard PCs with a Windows (NT4, 2000, XP, VISTA or 7)
operating system.
You can connect the PC to the front panel of a Gemstart using a standard serial port1
and a straight through 9 way cable with D type connectors. The program allows you
to do the following on a single Gemstart :
Issue Start & Stop commands.
Reset Trips & Alarms.
View its online system measurements such as currents, volts, & power.
Check the status of overload timers, input/output contacts, and last start
information.
Enter and modify all the Gemstarts configuration settings to suit your particular
contactor type and application requirement.
View historical data recorded in the Faults log.
Set up the Gemstart on a communications link enabling remote control and

retrieval of information. (See System Integration section 10 for more information)
It also allows you to set up a complete integrated system consisting of multiple

Gemstarts using the database within the Configuration Editor.
If you have a Gemstart 5 but do not have a copy of this software, please contact
COMECA, using the details given inside this document or directly download it from
the Gemstart5 maintenance website : www.gemstart.fr
For full details about how to use the GEMPRO software please refer to volume 3 Gemstart 5 GEMPRO - PC Control & Configuration Software Manual
If serial port is not available, an USB-to-RS232 adapter will perfectly fit
- 105 -
Gemstart 5
13 Instructions for installation, use and

maintenance
Conditions for transport and installation : please refer to Galaxis manual for
transporting, handling and installation of Low Voltage Switchgears.
The implementation of Gemstart5 products in Galaxis switchgears is made in our
engineering and design department following these requirements:
Distance between Gemstart5 and environnement greater than or equal to
10mm.
Distance between Gemstart5 and active parts tightening greater than or
equal to 13mm.
Gemstart5 body unit is fixed on a vertical DIN rail with RJ45 connector up.
Gemstart5 products are designed for an environment B.
Use : please refer to the Gemstart5 manuals. This device is intended to be used by
pre-trained staff. It is necessary for the staff to respect the normal security
procedures.
Maintenance : if a device is suspected to be defective (for example when it has been
physically damaged or when the status green LED is not continuously lit), it has to be
put out of service, and eventually the drawer can be replaced to ensure process
continuation.
Then, it is necessary to ensure that the suspected part will not be used
unintentionnally. Entrust it to authorised technicians care. In case of established
defect of a Gemstart5 product, proceed to an exchange, return the faulty product to
the supplier for expertise, with project number, drawer reference and configuration
file for this product.
Never dismantle the product ! Gemstart5 being a security device, only the
manufactuer is authorised to repair it.
The PAMM replacement (inside the fixed part) needs an autorisation to work in an
electrical environment.
Cleaning : with the device disconnected from alimentation, only use damp cloth to
clean external surface. Do not use abrasive product nor solvent. Do not wet
connectors.
- 106 -
Gemstart 5
Wiring : Gemstart5 have different connectors, which caracteristics are:
PHOENIX 1757048 1757158 Body connector: wire section 0,2 to 2,5
mm2 , minimal torque for each screw 0,5 Nm.
PHOENIX 1840324 Body connector : wire section 0,14 to 1,5 mm2 ,
minimal torque for each screw 0,22 Nm.
PHOENIX 1840335 IP Module connector : wire section 0,14 to 1,5 mm2 ,
PHOENIX 1757080 RTD Module connector : wire section 0,2 to 2,5 mm2 ,
Please refer to PHOENIX CONTACT technical documentation for connectors
characteristics.
- 107 -
Gemstart 5
14 Gemstart panel cutouts and mounting

details
- 108 -
Gemstart 5
- 109 -
Gemstart 5
15 Gemstart 5 Connectors pin outs

NOTE shaded groups indicate signal isolation groups
Body Unit - High Power connector
Pin
No.
Function
Earth
Control supply -
Control supply +
Motor supply
Pin 1
(GS5.3 and 5.4 only)

5
Motor supply +
(GS5.3 and 5.4 only)
Field I/P 5 -
Field I/P 5 +
Field I/P 6 -
Field I/P 6 +
10
Field I/P 7 -
11
Field I/P 7 +
12
Output 1
13
Output 2
14
Interlock -
15
Interlock +
16
Output 3
17
Output 3
18
Output 4
19
Output 4
20
Input 8/ESD -
21
Input 8/ESD +
L3
L1
Warning! If input 8 is used for the Emergency Shut Down (ESD) option (end of life)
to control output 4, the voltage applied to this input must be limited to 24V dc,
otherwise the output may be damaged.
- 110 -
Gemstart 5
Body Unit - Low Power Connector
Function
Pin No.
CBCT S1 (Not 5.1)
22
CBCT S2 (not 5.1)
23
Not connected
24
PTC (GS5.4)
25
PTC + (GS5.4)
26
PAMM (Gnd) blue
27
PAMM (Data) red
28
PAMM (Clock) white
29
Chassis I/P 1
30
Chassis I/P 2
31
Chassis I/P 3
32
Chassis I/P 4
33
Pin 22
Chassis
Common
I/P
34
TX/RX - [Profibus A]
35
TX/RX + [Profibus B]
36
RX - (4 wire)
37
RX + (4 wire)
38
Notes:
Do not earth the CBCT connections
L3
- 111 -
Gemstart 5
Input unit pin out
Pin No
Function
Earth
Field I/P 9 -
Field I/P 9 +
Field I/P 10 -
Field I/P 10 +
Field I/P 11 -
Field I/P 11 +
Field I/P 12-
Field I/P 12 +
Pin No
Function
10
RTD 1 +
11
RTD 1 -
12
RTD 1 + Sense
13
RTD 2 +
14
RTD 2 -
15
RTD 2 + Sense
16
RTD 3 +
17
RTD 3 -
18
RTD 3 + Sense
19
RTD 4 +
20
RTD 4 -
21
RTD 4 + Sense
22
RTD 5 +
23
RTD 5 -
24
RTD 5 + Sense
25
RTD 6 +
26
RTD 6 -
27
RTD 6 + Sense
Pin 1
Pin 10
- 112 -
Gemstart 5
16 Technical Specifications
16.1 Gemstart 5 Body units
High Voltage units
Power Supply
options
: 110V/240V AC &
Supply Range
: 110V AC -35%
Low Voltage units

24V DC - 48V DC
110V DC
24V DC -25%
to 240V AC +10% &
to 48V DC+25%
110V DC - 15%
to 110V DC +25%
Frequency
: 45-63 Hz & DC
DC
Power Consumption of : 5VA typical

unit
7.5 VA maximum
Mains input fuse
: 2A antisurge (Not user replaceable, should only fail in event of

module failure. Return to factory.)
Inrush current
: 8A max.
Supply Interruption
Ride-through
: 20ms (at minimum supply range.)
Inputs
Local inputs
nos. 1 to 4
: (All Gemstart 5 body units)

4 x local inputs supplied from internal 24V DC rail
Reaction time is better than 10ms
MuIti Voltage inputs : (Gemstart 5.1, 5.3 & 5.4 only)

1 x Interlock & 4 x Field inputs (nos. 5 to 8)
24 110V dc & 24 240V ac.
Input characteristics
Input voltage
Threshold voltage
Current consumption
24V DC
12V DC
4 mA DC
48V DC
12V DC
8 mA DC
130V DC
65V DC
2.5 mA DC
110 AC
55V AC
4 mA AC
230V AC
55V AC
8 mA AC
- 113 -
Gemstart 5
Outputs
(Gemstart 5.1, 5.3 & 5.4 only)
Contactor Outputs 1&2 : Rated Current 12A

Rated Voltage 250V AC
Max breaking voltage 440V AC
Max breaking capacity 4000VA
Make current ( max. 4s at duty cycle 10%) = 30A
peak inrush current (20ms) = 80A
Status Outputs 3&4
: Rated Current 6A
Rated Voltage 250V AC
Max breaking voltage 440V AC
Max breaking capacity 1500VA
Make current ( max. 4s at duty cycle 10%) = 15A
Phase Current
(Gemstart 5.3 = 2 phases, 5.4 = 3 phases)
Measurement method : Integral CTs for 0.5 -30 amps nominal, then in conjunction with
interposing CTs from 30 1000 amps nominal
Accuracy
: +/- 2% for 0.5 30A

+/- 5% up to max rating of 250A
Single phase tripping : Adjustable imbalance trip

Interposing CT rating
Class - 5P10,VA rating - 0.045 VA, Burden - 0,02 ohms
Earth Fault Current
(Gemstart 5.3 & 5.4 only)
Measurement method : CBCT input

Nominal secondary
current
0.02 A
Accuracy
: +/- 2% + selected CBCT error
Range
: From 0.2% to 500% of CBCT rating subject to the accuracy of

the CBCT
Measurement method : Residual (Gemstart 5.4 only)

Accuracy
: +/- 5% in range 0.1 - 30A.

EF Limit must be between 10% and 100% of FLC
CBCT rating
VA rating - 0.0156, Burden - 36 ohms. Do not earth the wiring.
Motor Voltage
(5.3 & 5.4 only)
Measurement method : Integral voltage transformer

range 110 240 Vac
Accuracy
: +/- 3% of nominal supply
- 114 -
Gemstart 5
Consumption
0.5VA
Power
(5.3 & 5.4 only)
Measurement method : V x A
Accuracy
: +/- 5%
Serial Communications Links

Modbus & Gembus
Format
: RS485 (2 or 4 wire for Modbus & 4 wire for Gembus)
Rate
: 4800 to 128k bits/second
Distance
: 1000m max.
Cable type
: Twin twisted pair with overall screen

Recommended type Belden 9729
Profibus DP V1
Format
: RS485 (2 wire)
Rate
: 1.5Mbits/second
Distance
: 1000m max.
Cable type
: Profibus standard
Connections
High power
connections
: Plugs, 12 A , 250 V , space: 5,08, 21-position , Screw connection
wire size
: min 0.2 2.5 max
Low power
connections
: Plugs, 8 A , 160 V , space: 3,81, 17-position , Screw connection
wire size
: min 0.14 1.5 max
PC program interface : RS232, 9 way D type

Mechanical
Dimensions
: 112(W) x 138(H) x 54(D) mm
Weight
: 500g
IP Rating
: IP20
- 115 -
Gemstart 5
16.2 Extension units

Display units:
LED and LCD modules 5 LEDs :
1 x Green UNIT HEALTHY = led 1
4 x tri-coloured configurable LEDs = LEDs 2 -5
initial default configuration :
led 2= Red - RUNNING A
led 3 =Green - STOPPED A
led 4 = Red - TRIPPED & Yellow - WARN
and Red Flashing - LATCHED TRIPPED &
Yellow Flashing - ALARM
led 5 = Green - SERIAL LINK IN CONTROL
Power Supply
: Fed from power supply in Body unit via 8 way lead
Mechanical
Weight
: 150g
Dimensions
: 83(W) x 98(H) x 32(D) mm

(80mm(D) including Stop Switch)
IP Rating
: IP54 from front when mounted
LCD module
: 124 x 64 pixel back lit graphical LCD
Input unit
multi-voltage inputs
: Ratings exactly the same as input nos. 5 to 8 above.
no. 9 to12
Power Supply
Connections
High power
connections
: Plugs, 12 A , 250 V , space: 5,08, 9 -position , Screw connection
wire size
: min 0.2 2.5 max
Mechanical
Weight
: 160g
Dimensions
: 112(W) x 115(H) x 50(D) mm
IP Rating
: IP20
- 116 -
Gemstart 5
RTD / Input unit
Inputs
multi-voltage inputs
: Ratings exactly the same as input nos. 5 to 8 above.
no. 9 to12
Power Supply
RTD
Measurement method
Constant current source - 340 uA
Accuracy
+/- 1C or +/- 0.385
Connections
Digital input
connections
: Plugs, 12 A , 250 V , space: 5,08, 9 -position , Screw connection
wire size
: min 0.2 2.5 max
RTD connections
Plugs, 8 A , 160 V , space: 3,81, 17-position , Screw connection
Wire size
min 0.14 1.5 max
Mechanical
Weight
: 200g
Dimensions
: 112(W) x 115(H) x 50(D) mm
IP Rating
: IP20
- 117 -
Gemstart 5
16.3 Environmental
16.3.1
EMC
16.3.1.1
Emissions
EN 55011
Conducted Emission
Class A
EN 55011
Radiated emission
Class A
16.3.1.2
Susceptibility
EN61000-4-2
Electrostatic discharge contact 4kV, Air 8kV
Level 3
EN61000-4-3
Radiated electromagnetic fields10V/m
Level 3
EN61000-4-4
Fast transient bursts 2kV power, 1kV signal
Level 4
EN61000-4-5
Surge 4kV power, 2kV inputs and signals
Level 3
EN61000-4-6
Conducted interference 10V
Level 3
EN61000-4-8
Power frequency magnetic field 30A/m
Level 4
EN61000-4-11
Voltage drop out
ENV50204
Radiated field pulse modulated 10V/m
16.3.1.3
RTD Module (additional testing)
IEC 61000-4-16
16.3.2
Mains frequency voltage 30V cont, 300V 1 sec
Vibration
1.0g
Climatic
-5C to + 60C
Operating
-40C to + 85C
Storage
IEC 68-2-3
Damp heat steady state
16.3.4
Level 4
Mechanical
IEC 68-2-6 test FC
16.3.3
Level 3
5 to 95 % RH
Fire and smoke
UL94 V0
IEC 60695-2-10 and IEC 60695-2-11
Fire Hazard Testing
- 118 -
650C

Route de Givry ZI La Garenne F 71880 Chtenoy-le-Royal Tel.: +33 (0)3 85 98 22 00 Fax+33 (0)3 85 98 22 01
Internet: www.gemstart.fr

Gemstart 5 - Vol 1 - User Guide

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Gemstart 5 - Vol 1 - User Guide

Caricato da

Copyright:

Formati disponibili

Publication date : October 2011

We reserve the right to supply

Health and Safety

Installation and commissioning

Spare parts supply

Service and maintenance

Refurbishment and modification

Added External Module Protection

Updated Default table

New RTD data Group 11

Information about RTD on Network

New basic schematic diagram

Added PAMM wire color

Profibus profiles update

Highlighted important points

Added ESD warning message on power connector page

Added RTD Status Word to network

Added Auto-restart extended function (p34, 55)

Information ESD versions end of life

Acronyms and Abbreviations

Symbols used within the Technical Handbook

About this Guide

Gemstart 5 - Specification Reference Manual

Gemstart 5 - GEMPRO - PC Control & Configuration Software Manual

MAIN FEATURES ........................................................................................................................................... 13

MAIN COMPONENT PARTS ........................................................................................................................ 14

HARDWARE DETAILS .................................................................................................................................. 15

BODY UNITS ................................................................................................................................................ 16

POWER SUPPLIES ....................................................................................................................................... 17

OPTIONAL EXTENSION MODULES ........................................................................................................ 17

INTERCONNECTIONS BETWEEN BODY UNITS AND EXTENSION MODULES .............................. 17

TYPICAL ARRANGEMENT OF GEMSTART INSTALLED IN A MCC CHASSIS ................................ 18

BASIC SCHEMATIC DIAGRAM ................................................................................................................ 19

PROTECTION AND CONTROL FUNCTIONS .......................................................................................... 21

CONTACTOR TYPE FUNCTIONS ............................................................................................................. 21

INPUT FUNCTIONS AND CONFIGURATION OPTIONS ........................................................................ 22

PROTECTION FUNCTIONS ........................................................................................................................ 24

INPUTS AND OUTPUTS ................................................................................................................................ 25

Multi Voltage Field inputs ................................................................................................................... 25

Multi Voltage Interlock input ............................................................................................................... 26

Default mapping of Inputs...................................................................................................................... 26

DIGITAL OUTPUTS ..................................................................................................................................... 27

Hardware Outputs 1 to 4 Configuration Options .................................................................................. 28

Hardware Outputs 1 to 4 sense .............................................................................................................. 29

ANALOGUE INPUTS ................................................................................................................................... 29

Phase current inputs .............................................................................................................................. 29

FLC Setting ............................................................................................................................................ 30

ALC Setting ............................................................................................................................................ 30

Motor Starting Current .......................................................................................................................... 30

Contactor Rating .................................................................................................................................... 31

Thermal Overload Curves ...................................................................................................................... 31

Earth fault current input (CBCT)........................................................................................................... 34

Residual Earth Fault (5.4 only) ............................................................................................................. 34

Thermistor (PTC) input (Gemstart 5.4 only) ...................................................................................... 35

6.3.10 Motor supply monitoring ....................................................................................................................... 35

DISPLAY DATA CONFIGURATION. ........................................................................................................ 49

GEMSTART 5 FAULT MESSAGES ............................................................................................................ 50

GEMSTART FATAL ERRORS .................................................................................................................... 59

WATCHDOG FUNCTIONS ........................................................................................................................... 61

EVENT RECORDS .......................................................................................................................................... 62

MOTOR HISTORY ....................................................................................................................................... 62

EVENT HISTORY ........................................................................................................................................ 62

PLANT ASSOCIATED MEMORY MODULE (PAMM)............................................................................. 62