Gemstart 5

Volume 3 – GEMPRO

276192-113 Rev. I

Publication date: March 2020

 Gemstart 5

Volume 3 – GEMPRO 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 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 Châtenoy-le-Royal
France

Tel.: +33 (0)3 85 98 22 00

Fax: +33 (0)3 85 98 22 01

Web: www.comeca-group.com

Our policy is one of continuous product development. We reserve the right to supply
equipment that may vary from that described.
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.

Gemstart5 declarations of conformity are available on the internet site or on demand.

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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. Modification
without COMECA’s 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 at the address below:

COMECA Equipements Basse Tension

Route de Givry
ZI La Garenne
F71880 Châtenoy-le-Royal
France

Tel.: +33 (0)3 85 98 22 00

Fax: +33 (0)3 85 98 22 01

Web: www.comeca-group.com

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Customer Services
COMECA’s 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

COMECA’s 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 to
discuss existing equipment, please help us by having the following information available:
The original COMECA works order number or
The unit serial number and the unit type and voltage
When you have the information listed above, please contact us at the address below:

COMECA Equipements Basse Tension

Route de Givry
ZI La Garenne
F71880 Châtenoy-le-Royal
France

Tel.: +33 (0)3 85 98 22 00

Fax: +33 (0)3 85 98 22 01

Web: www.comeca-group.com

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Table of Revisions

Edition Description Date

Original issue May 2006

Added External Module Protection

A July 2006
Added 2nd Reset Input
September
B Supply Ride-Through Extension
2006
Added new Profibus profile code
explaination
Warning message about Firmware
C Update March 2007
Changing PAMM information
Minor corrections
Note on declaration of conformity
D Firmware update instruction April 2008
Note for Gempro Profibus
New logo
E Reviewed minimum system January 2010
requirements
Added Inputs Supply Volatile (p61)
Added Contactor Settling Time
F
(p62)
Added Profibus multiplier (p74)
Added contactor settling time info
G (p62) October 2011
Added Modbus 4-wire (p70)
Add of two additional status options
H January 2018
for the outputs (p62)
-Update software requirements for
GemPRO 4.9.0.0 and later versions
(p10 & 12).
-GemPRO Profibus communication
I via Siemens CP card functionality March 2020
removed for GemPRO 4.9.0.0
version (p12).
-Print/export functionality software
requirement updated (p12).

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Acronyms and Abbreviations

Item Meaning
A Amperes
ac Alternating Current
ALC Actual Load Current
CT Current Transformer
dc Direct Current
FLC Full Load Current
I/O Input / Output
kA Kilo Ampere
kV Kilo Volt
LED Light Emitting Diode
LCD Liquid Crystal Display
mA Milli Ampere
mm Milli Metre
ms Milli Second
MW Mega Watt
Ops Operations
A Micro Amperes
sec. Second
V Volt
VT Voltage Transformer

Symbols used within the Technical Handbook

ADVICE: information CAUTION: precautions to be

intended to assist in taken to avoid damaging the
performing specified tasks equipment

YOUR ATTENTION IS DANGER, ELECTRICITY:

DRAWN: specific points precautions to be taken to avoid
that should be noted. injury to personnel.

MECHANICAL DANGER:
precautions to be taken to
avoid injury to personnel.

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Table of Contents
1 ABOUT THIS MANUAL ............................................................................................................................ 9
2 INTRODUCTION ..................................................................................................................................... 10
2.1 DEFINITIONS .......................................................................................................................................... 10
3 GEMPRO INSTALLATION .................................................................................................................... 12
3.1 INSTALLATION POLICY .......................................................................................................................... 12
3.2 MINIMUM SYSTEM REQUIREMENTS ....................................................................................................... 12
3.3 GEMPRO INSTALLATION ..................................................................................................................... 12
3.4 UNINSTALLING GEMPRO ..................................................................................................................... 16
3.5 INSTALLING THE SECURITY KEY DRIVER (OPTIONAL) .......................................................................... 16
4 USING GEMPRO ...................................................................................................................................... 17
4.1 START MENU OPTIONS .......................................................................................................................... 17
4.2 STARTING GEMPRO ............................................................................................................................. 18
4.3 CONNECTING TO GEMSTART ................................................................................................................. 18
4.4 GEMPRO MAIN SCREEN ...................................................................................................................... 21
4.5 LANGUAGE OPTIONS ............................................................................................................................. 22
4.6 SECURITY OPTIONS ............................................................................................................................... 23
5 MONITORING GEMSTART DATA ...................................................................................................... 24
5.1 CURRENTS ............................................................................................................................................. 25
5.2 VOLTAGE AND POWER........................................................................................................................... 26
5.3 TIMER AND COUNTERS .......................................................................................................................... 27
5.4 TEMPERATURE SENSORS ....................................................................................................................... 28
5.5 FAULTS AND HISTORY ........................................................................................................................... 29
5.6 SERIAL LINK .......................................................................................................................................... 34
5.7 MAINTENANCE ...................................................................................................................................... 37
5.8 COMMISSIONING .................................................................................................................................... 38
6 CONTROLLING GEMSTART ............................................................................................................... 40
6.1 LEVELS OF CONTROL............................................................................................................................. 40
7 CONFIGURING GEMSTART ................................................................................................................ 43
7.1 PROJECT DATABASE .............................................................................................................................. 43
7.2 OFFLINE CONFIGURATION ..................................................................................................................... 44
7.3 ONLINE EDIT ......................................................................................................................................... 44
7.4 LEVELS OF CONTROL............................................................................................................................. 44
7.5 CONFIGURATION WINDOW (ONLINE AND OFFLINE) .............................................................................. 45
7.6 CONFIGURATION FORMS ....................................................................................................................... 51
8 GEMSTART WIZARDS........................................................................................................................... 68

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8.1 RESET CONFIGURATION ........................................................................................................................ 69
8.2 CHASSIS WIZARD .................................................................................................................................. 70
8.3 MOTOR WIZARD .................................................................................................................................... 75
8.4 PROTECTION WIZARD ............................................................................................................................ 82
9 SPECIAL OPERATIONS ......................................................................................................................... 93
9.1 UPDATING GEMSTART FIRMWARE ........................................................................................................ 93
9.2 RECOVERING A PARTIALLY UPDATED GEMSTART ................................................................................ 96
9.3 ADDING A NEW LANGUAGE TO GEMPRO ............................................................................................. 98
9.4 REPLACING A FAULTY PAMM ............................................................................................................ 101
9.5 UPDATING THE GEMSTART USER DEFINED LANGUAGE....................................................................... 103
9.6 UPDATING THE GEMSTART USER DEFINED CHARACTER SET .............................................................. 107
10 APPENDIX A – CONFIGURATION PRINTOUT .............................................................................. 111
11 INDEX ...................................................................................................................................................... 114

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1 About this manual

This reference manual contains information about GEMPRO, the PC based monitoring,
control and configuration package.

Readership:

This publication is for the GEMPRO 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 Gemstart’s settings.

Related publications:

Volume 1: Gemstart 5 User Guide

Volume 1 is for the general engineer and user who will install, commission, use and maintain
Gemstart 5

Volume 2: Gemstart 5 - Specification Reference Manual

Volume 2 is for use by expert engineers who will be setting up Gemstart systems.

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2 Introduction
2.1 Definitions
Gemstart 5 is provided with COMECA’s bespoke Monitoring, Control and Configuration
software program “GEMPRO” which is supplied to the User under freeware license. It runs
on most standard PC’s with a Windows VISTA or 7, 8, 10 (by disabling the windows
XP SP2 compatibility mode).
Note: If you have already installed GemPRO version 4.8.4.0 or earlier on your computer,
using GemPRO 4.9.0.0 version or later, make sure to disable the compatibility mode XP SP2
to get an optimum operation.

You can connect the PC to the front panel of a Gemstart using a standard PC serial port and
a straight through male to female 9 way cable with D type connectors. GEMPRO allows you
to do the following on the connected Gemstart:
Monitoring
 View system measurements such as currents, volts, & power
 Check the status of overload timers, input counters and starts in previous hour
 View a full list of the active faults
 View historical data recorded in the Faults log
 View maintenance data
 View commissioning data

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Control
 Issue Start & Stop commands
 Reset Trips & Alarms
Configuration
 Enter and modify all the Gemstart’s configuration settings to suit your particular
contactor type and application requirement
 Set up the Gemstart on a communications link enabling remote control and
retrieval of information. (See System Integration section 10, in Gemstart 5 volume
1 for more information)

This reference manual gives specific details about the operation of GEMPRO. This can be
split into the following main areas:
 GEMPRO Installation
 Setting Up GEMPRO
 Connecting to Gemstart
 Monitoring Gemstart Data
 Controlling Gemstart (Start / Stop / Reset)
 Configuring Gemstart

The configuration editor is a major part of GEMPRO. The GEMPRO Configuration Editor can
be “called” as an ActiveX component from other applications such as Gemview.

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3 GEMPRO Installation
3.1 Installation Policy
GEMPRO is the property of COMECA and is freeware.
GEMPRO is provided as a tool for configuring Gemstart 5 and you are licensed to install
GEMPRO on as many PC’s as you wish.
If you are concerned about the security issues that multiple GEMPRO installations introduce
then you can use GEMPRO with a Security Key. The Security Key can only be purchased
from COMECA and prevents control and configuration changes from a GEMPRO package
that is not Key enabled.
Note: Profibus communication using Siemens CP card through GemPRO is available
just for GemPRO 4.8.4.0 or earlier with Windows XP or 2000.

3.2 Minimum System Requirements

GEMPRO does not use a lot of processing power so most PC’s or laptops can be used.

Operating System Microsoft Windows® VISTA, 7, 8, 10

CPU Pentium® type
Display Resolution 1024x768 or above
For Printing and Exporting of Microsoft Excel® is not mandatory to export or
Configuration print configurations and this for GemPro 4.9.0.0
and later versions.
To use the Security Key USB Port
Updates Internet connection

3.3 GEMPRO Installation

Two installation programs in English or French are provided.
Each program installs the same GEMPRO files but the InstallShield messages are in the
relevant language and GEMPRO starts in the appropriate language.
After installation you can change GEMPRO between English and French as you wish.

Administrator Rights are required on some operating systems to install GEMPRO.

To begin installation download install file from the website www.comeca-group.com and run
GemproEN_X_X_X_X.exe or GemproFR_X_X_X_X.exe (_X_X_X_X is the version number).

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You see the installation welcome screen:

Press Next>.

Accept the agreement and press Next>.

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Enter your user name and your company name.

You must decide how many users of this PC should have GEMPRO added to their start
menu.

Press Next>.

This is the default installation directory. If you want to install in a different directory then
select Change.

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Press Next>.

Check the settings are correct then press Install.

Installation is now complete. Press Finish.

Files are only installed in the Destination Folder.

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Two initialisation files are created on the “Public” user Profile under “Public Documents”
directory.

GSHhp.ini Contains the GEMPRO connection settings and the position

of the data monitoring windows.
GSConEdX.ini Contains the location and name of the Project file and the
language to be used by GEMPRO and the Configuration
Editor.

3.4 Uninstalling GEMPRO

To remove GEMPRO open the Control Panel and select Add/Remove Programs. Select
GEMPRO and click “Remove”.

3.5 Installing the Security Key Driver (Optional)

You only need to install the Security Key Driver if you are going to use the Security Key.

Administrator Rights are required to install the driver for the Security Key. Once you have
installed GEMPRO you can install the Security Key Driver from the Start Menu.

Start > Programs > GEMPRO > Install Sentinel SuperPro Driver (Security Key)

This is a fully automatic installation which should end with a success message.

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4 Using GEMPRO
4.1 Start Menu Options
Installing GEMPRO creates a new group of shortcuts in the Start button menus and a single
shortcut to GEMPRO on the Desktop.
Click Start / Programs / GEMPRO and you see the shortcuts installed for GEMPRO.

These shortcuts are used for the following tasks:

GEMPRO This is the main shortcut. Starts the monitor, control and configuration
program.

Install SuperPro This starts the automatic installation of the optional Security Key driver.
Driver (Security Installing this driver allows the Security Key to be used. Note: Installing
Key) the driver does not force you to use a Key but without the driver you
cannot use a Key.

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4.2 Starting GEMPRO

Click Start / Programs / GEMPRO / GEMPRO or double click the GEMPRO icon on the
desktop.
GEMPRO displays the main screen and tries to connect to Gemstart 5 via the previously
used connection. e.g. COM7.

4.3 Connecting to Gemstart

The communication method available to connect to Gemstart 5 is:
 RS232 via one of the COM ports
After first installation GEMPRO defaults to scanning the available COM ports.
4.3.1 Connecting Via COM Port

Profibus Link

RS232 RS232 RS232

Access any
Gemstart on the link
via the Profibus link (Gemview)

Access the connected

Gemstart via a COM port

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GEMPRO tries to connect via COM7. If a Gemstart 5 is not found within 4s then it tries
COM2 then any other COM ports that are present on the PC. It continues to cycle round
the available COM ports until a Gemstart 5 is found.
A straight through 9 pin D-Type male to 9 pin D-Type Female cable is required. The cable
must not have nuts fitted to the male end.
A suitable cable such as:
 11.01.6218 from Roline
If the same COM port is always used then you can lock the COM port used by selecting
the “GEMPRO Connection” button…

…and selecting the relevant COM port, and ticking “Lock Channel”. This prevents GEMPRO
scanning the other COM ports when a connection is not found.

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4.3.2 Multiple GEMPRO Connections
GEMPRO can connect to Gemstart via RS232 (via the Gemstart front port) or by Profibus
Gemview (the EWS package).

It is therefore important to understand how each of these programs will interact.

Gemstart can operate with one Gemview and one GEMPRO’s connected using RS232.
Each package can monitor and reset faults from monitor mode without taking control.

The first application to request control will lock out all the other applications. When an
application is locked out it cannot send any reset commands but it can still monitor the data.

Gemstart can indicate which application is in control when you select “status” for the LCD.
Options are:
* GEMPRO for GEMPRO control via RS232
* Profibus Gemview for Gemview control via Profibus

GEMPRO can also indicate the control status.

* Monitor Monitoring and could request control.

* Config Mode Requesting control but not in control. Can edit
configuration.
* GEMPRO in Control Requesting and in control.
* Locked (No Key) A Key is required (by Gemstart) for motor
control and configuration changes
* Locked (RS232 GEMPRO Connected) Another GEMPRO is connected to the RS232
port of Gemstart (version <= F05)
* Locked (Front Port) Locked out by a GEMPRO in control
connected to the Gemstart RS232 port
* Locked (Profibus Gemview) Locked out by Gemview in control and
connected to the Gemstart Profibus port
* Communications Lost The link to Gemstart has been lost.

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4.4 GEMPRO Main Screen

The main GEMPRO screen has several parts to it.
 The Window Heading contains:
The version of GEMPRO (4.9.0.0 in this example)
The Motor Tag (Pump1)
The Motor Rating (Not displayed here)
The Motor FLC (20.5 A)
 The Window Footer has a status bar which displays:
The connection status (connected via COM3)
The Gemstart fault status (Available)
The Motor status (Running)
The GEMPRO Level of Control (Gempro in control)
The status of the Security Key (No Key)
 Control Gemstart gives access to the Control / Start / Stop / Reset buttons
 Edit (or View) Configuration and Offline Edit open the Configuration Editor.
 Currents, Voltage & Power, Timer & Counter, Faults & History, Serial Link,
Maintenance and Commissioning all give access to the data in the connected
Gemstart 5. You can open any number of these windows at the same time.
However the screen soon fills up.
 GEMPRO Connection allows the GEMPRO connection method to be defined.
E.g. COM port.
 Exit GEMPRO closes the GEMPRO application.
 Windows Reminder re-opens previous session windows.
Window Heading

Gemstart 5
Configuration

Gemstart 5
Data

Windows
reminder

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4.4.1 Button Bar
Once you have a few windows open the GEMPRO main screen becomes hidden and this
makes it difficult to select other windows. For easy access an “Always on Top” Button Bar is
provided which has miniature copies of all the buttons.

There is one button on the Button Bar that is not present on the main screen. The “Control”
button is a copy of the Control button in the Control Gemstart window.
The “Control” button is a Padlock when GEMPRO is not controlling Gemstart 5. Pressing the
Padlock button requests control of Gemstart 5. If Gemstart 5 grants control to GEMPRO
then the Padlock changes to a Key. Pressing the Control button again releases GEMPRO
control and the button changes back to a Padlock. See Levels of Control explanation later in
the manual.

4.5 Language Options

The language of the GEMPRO and Configuration Editor windows can be defined from the
online or offline Configuration Editor.

The list of available language is shown here. Changes to this item are implemented
immediately and are remember for the next session of GEMPRO.

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4.6 Security Options

The security key allows an installation to have a high level of access protection on all or
some of the Gemstart units. The key can be used to restrict access to changing
configuration and controlling the motor to authorised personnel only.

Physically the key plugs into the USB port on the PC.

Each Gemstart 5 individually stores the security setting (not the PC). The Level of Security is
one of the Gemstart configuration settings. This allows some parts of an installation to be
protected with a Key whilst other parts allow general access.

To make use of the additional security offered by the Key you must set the “Key Required”
configuration item in the GEMPRO window to “Required”.

The “Key Required” option can be changed in Offline Mode without a Key present but the
configuration can only be downloaded to Gemstart if a Key is present when the down load
occurs. This prevents clearing or accidental setting of this requirement when there is no Key
available.

Key Required can only be changed in Online Edit mode when a Key is present.

Once the configuration has be set to “Key Required” then control and configuration changes
can only be performed while the Key is present on the USB link.

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5 Monitoring Gemstart Data

While GEMPRO is connected to Gemstart 5 (via RS232) GEMPRO can display all the
information produced by Gemstart. The data is organised into groupings of similar data.
 Currents – Current measurements
 Voltage and Power – Voltage and Power measurements
 Timers and Counters – Various timers and counter
 Faults and History – Active faults and a history of trips
 Serial Link – Statistics for both the Host and GEMPRO links
 Maintenance – Useful data for the maintenance engineer
 Commissioning – Useful data during commissioning

The monitoring windows can be opened from the main GEMPRO screen or from the button
bar.

The monitoring windows can all be opened at the same time and positioned around the
screen for best viewing. The placement of these windows is remembered and the next time
the window is opened it appears in the same place.

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5.1 Currents

Individual Phase measurements are based on the CT readings. On Gemstart 5.3 where
there are only 2 CT’s fitted the Phase 2 current is a residual sum of CT’s 1 and 3. On
Gemstart 5.1, no measurement is made.
The Highest Phase current is the highest of the 3 individual phase readings. This is the
current that is used for most protection items.
The Average is the average of the 3 phase currents.
Each of the above current measurements are displayed as:
%FLC. A percentage of the configured Full Load Current
%ALC. A percentage of the configured Actual Load Current.
Amps. The current in Amps adjusted for external CT’s if configured.

Imbalance current is the difference between the highest and lowest phase current and is
displayed as a percentage of the configured fault limit. I.e. 100% Set Point is the fault limit.

Thermal Content is a model of the heating effects in the motor and is displayed as a
percentage of the Overload limit. I.e. 100% Set Point is the fault limit.

Earth Current is calculated from the external CBCT and is displayed in Amps and as a
percent of the Earth Current limit. I.e. 100% Set Point is the fault limit.

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5.2 Voltage and Power

Monitored Voltage is the voltage measured by Gemstart on the Motor Voltage input. This
voltage is then converted to the Motor Voltage based on the configured voltages for the
motor and for Gemstart.

Motor Power is calculated from the motor voltage and the phase currents. The percentage
reading is a percentage of the configured motor power rating.

Power Factor is derived from the ratio of the motor power to apparent power. Power flow is
always assumed to be positive and the power factor is always displayed as positive.

The kWh Meter is a cumulative total based on the Motor Power. The kWh meter can be
reset from the Maintenance Window.

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5.3 Timer and Counters

5.3.1 Timers
Each Timer is greyed out unless it is active.
The Overload Trip timer is an estimate of how much time is left before the Thermal Content
reaches 100% and an overload trip occurs.
The Restart Inhibit timer is an estimate of how much time is left before there is enough spare
Thermal Content to allow another start. This is based on how much Thermal Content was
used in the last start.
The Reset Inhibit timer is the time left before this configured time delay has elapsed.
The Starts / Hour timer is the time left before the Starts/Hour protection will allow another
start.
The Auto Restart timer is a count down to an automatic close by the Auto Restart feature.

5.3.2 Counters
Inputs counters 1 to 3 are 3 counters that can be configured to monitor the activity of any
digital input. They can count up to 65,565,999 each. The counter can be reset from this
window if GEMPRO has a sufficient level of control. See Levels of Control explanation later
in the manual.
Starts in the Last Hour is a count of the starts in the last hour. Gemstart can count up to 255
in any 15 minute period.

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5.4 Temperature Sensors

This shows the status of the PTC input on Gemstart 5.4. Options are:
 Not Available – Gemstart is not 5.4
 Cold – the PTC is low resistance
 Hot – the PTC is high resistance
 Short Circuit – the resistance is too low
The status of the RTD unit is shown. This indicates if the RTD Unit is connected. In case of
the loss of this connection, a protection can be activated (in Fuses and Contactor,
configuration editor).
The 6 RTD’s are grouped into two groups of 3. The group temperature shows the highest of
the 3 CT readings in the group.
The temperature of each RTD is shown and, if the protection is enabled, the fault level is
shown.
The following special conditions are indicated for the RTD inputs.
 Not Available – the RTD unit is not connected or the group temperature cannot
be calculated.
 Not Connected – the RTD+ input is not connected to RTD common
 Short Circuit – the RTD resistance is too low
 Open Circuit – the RTD resistance is too high

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5.5 Faults and History

5.5.1 Fault List

This view shows all the faults that are present on Gemstart 5.
* Latched Trips (LTrips) are faults that stop the motor and prevent Gemstart from starting it
again. Pressing Reset Trips clears these faults. If the fault is still present the fault returns.
* Self Clearing Trips (Trips) are faults that are continuously monitored. If the fault goes away
the fault report is removed (i.e. Self Clearing). A Trip stops the motor and prevents it from
starting again as long as the fault is still present. Reset Trips will not clear these faults.
* Latched Alarms (Alarms) are warning messages that must be reset. Alarms do not affect
control of the motor. Pressing Reset Trips clears these faults. If the fault is still present the
fault report returns.
* Self Clearing Warnings (Warnings) are faults that are continuously monitored. If the fault
goes away the fault report is removed (i.e. Self Clearing). A Warning does not affect control
of the motor. Reset Trips has no effect on Warnings.

Trip Counters
The 4 trip counters count the number of faults that have occurred in that group. The list of
faults in Volume 1 defines which faults are included in each group. These counters can be
reset from the Maintenance Window.

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5.5.2 Trip History

The Trip History shows the last 16 Trips (Latched or Self Clearing) that stopped the motor. A
trip that occurs while the motor is stopped is not stored in this list. The faults are listed with
the most recent Trip at the top of the list. Each fault has the following information:
 Severity. This can only be Trip or Latched Trip
 Fault. This is the protection type that has created the Trip
 Time. This is the time that the trip occurred. There are 3 levels of accuracy for
this time and this is covered below
 Highest Phase Current. This is the highest phase current flowing when the fault
occurred

Gemstart 5 Time
Gemstart 5 maintains the time internally while it is powered. After a power off and on, the
time continues to be maintained with no adjustment for the time that Gemstart was powered
down.
GEMPRO automatically updates the time in Gemstart if the time in Gemstart has not been
updated since Gemstart was powered on.
The time in Gemstart is displayed by GEMPRO and can be updated with the PC time by
pressing the Update Gemstart Time. Gemstart 5 allow time synchronisation from the
Modbus or Profibus communication links.
The levels of time accuracy are:
 Synchronised. The time has been updated from Modbus or Profibus in the last
100s. A Synchronised time is within +/- 10ms of the time source
 Estimate. Gemstart time has been updated since the last power on but a
Synchronised Time message has not been received in the last 100s
 Invalid. The time of the fault is not correct because it happened between a power
up and down of Gemstart when no time messages were received

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5.5.3 Event History

The Event History shows the events that have occurred to change the status of the motor.
The following events are recorded:

Events Comments
Start A A start command has been actioned.
A start command has been actioned. The B contactor is used for Reverse,
Start B
High Speed or to close a motor operated valve.
Stop A stop command has been actioned.
Gemstart When Gemstart powers up it recovers the power down time from the
Power Up PAMM and generates a power down and power up event. The power
Gemstart down event is always stored as an estimated time. The power up time will
Power Down be updated later when a time message is received.

Time This event is generated if time was not synchronised before a time sync
Synchronised message was received.
If a time sync message is not received within 100s of the previous time
Time Sync Lost
sync message then the accuracy in Gemstart may be outside +/- 10ms.
Start A If the slow down delay is configured and active when a Start command is
Delayed received the Start command is delayed. The Start Delayed event is
generated when the Start command is received. Once the slow down
Start B delay has elapsed a new Start command is automatically generated by
Delayed Gemstart and is shown in the event history with a Delayed Action source.
If the current is over the contactor protection threshold and a stop
command is issued or a trip occurs then the stop is delayed until the
Stop Delayed current drops or the fuse has had time to blow. At the end of the delay
Gemstart automatically generates a new stop command which is shown in
the event history with a Delayed Action source.

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Events Comments
Gemstart has detected that the motor voltage has failed. This event is
Motor Supply
usually replaced by the Gemstart Power Down event if the time between
Fail
the two events is not long enough to update the PAMM.
Motor Supply
Gemstart has detected that the motor voltage has recovered.
Recovery

The following sources are recorded:

Events Comments
Protection A protection item has caused the motor to trip. This source only produces
stops.
Serial Link The control system has started or stopped the motor via the serial link.
GEMPRO GEMPRO has started or stopped the motor.
Local Manual Gemstart is set up for Local/Remote manual controls and the local controls
(Stop A / Start A) have started or stopped the motor.
Remote Gemstart is set up for Local/Remote manual controls and the remote
Manual controls (Stop B / Start B) have started or stopped the motor.
Emergency An emergency start input has been activated.
AutoRestart This source generates a stop after the supply ride through time and
generates a start after the delayed start time.
Delayed When a start or stop is delayed due to Slow Down, Auto Acceleration or
Action Contactor Protection then the Delayed Action source records when the
actual stop or start is actioned.
Manual Test A manual start or stop command was actioned while the chassis was in the
test position.
Manual A manual start or stop command was actioned. i.e. Not configured for
Local/Remote.

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Event History Example.

We can look at the event history in the example above in more detail. We shall start with
event 16 which is the oldest event. For this example we need to know:
 Gemstart is configured as a Forward/Reverse motor
 Slow Down time is 4s
 Auto Restart delay is 5s.
Event Comments
16
A supply dip of 316ms occurred. The motor was not affected. (Already stopped)
15
14 The motor was put in reverse from manual mode.
13 The motor was stopped from manual mode.
A forward command was sent from manual mode but it is being delayed to allow
12
the motor to slow down from reverse.
11 The delayed start command is actioned 4s after the motor was stopped.
A protection trip has stopped the motor. The trip history will indicate the source of
10
the trip.
9 A start command was sent from GEMPRO.
8
A supply dip of 98ms did not affect the motor.
7
6
A supply dip of 497ms caused the motor to be stopped after the supply dip ride
5
through time of 200ms.
4
3 Auto Restart started the motor 5s after the supply had recovered.
2 A protection trip occurred.
1 The serial link started the motor in reverse.

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5.6 Serial Link

5.6.1 Common Data
The format of the serial link window changes depending on the configured protocol. This
screenshot shows the data that is common to all 3 protocols.

Active Protocol shows which protocol is currently active.

Command from the Link shows, in text, the last motor command that was received from
the active protocol.
Tx Fault Code on Link shows the fault code that is sent to the Protocol Master. This allows
the data in the Protocol Master to be verified. The first number is the fault severity and is
sent in the high byte of data. The second number is the fault code and is sent in the low byte
of data.
Link Timeout Timer shows the condition and time left on the timeout timer since the last
good message seen. If this timer reaches zero then the Link has failed.
Rx Timeouts is a count of the number of times the link has failed. This value is reset by the
Reset Link Statistic button.
Further advanced information is available about the status of the serial link. This information
is for systems integrators and is detailed in the following sections.
5.6.2 Profibus
This frame contains detailed information about the status of the Profibus serial link. This
information is for systems integrators.

The Rx Data frame contains the data received from the Profibus Master.
 Profile Type is the data format definition requested by the Profibus Master. Since
Gemstart5 firmware H04 and Gempro 4.6.3.0, the profile type is given by a
hexadecimal code. See Profibus GSD file for signification.
 The remaining values are the numerical values of the data received from the Profibus
Master.
The Profibus Status Flags give an indication of the low level status of the Profibus driver
within Gemstart 5. The following flags may help debugging.

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 Profibus Initialised, C0 Enabled and C2 Enabled. If these flags are not all set then
there is an internal error within Gemstart 5.
 New Parameters Received. Set if Profibus Master has established communications
with this Gemstart since Gemstart was powered up.
 V1 Parameters OK. Set if the configuration setting passed to Gemstart by the
Profibus Master were valid. The parameters can be seen elsewhere on this screen.
 I/O Config Changed. Set if the last Profibus connection changed the V1 parameters.
 Alarms Enabled. Set if the Profibus Master can Handle Alarm reporting.

The Parameters & Config frame shows the parameters and Profibus configuration received
from the Profibus Master. Refer to Profibus Specifications for a definition of these bits. Nota:
since Gempro 4.6.3.0, Config bytes are 4 instead of 3.
The Profibus Messages frame gives an indication of the type of messages being processed
and the frequency of these messages. The left column number is the number of data read
messages by the Profibus Master. The right column is the number of write messages sent by
the Profibus Master.
 Cyclic data is the data that is regularly exchanged with the Profibus Master.
 Acyclic data is the data that is additionally requested by the Profibus Master. This
would normally only occur if the Profibus Master is gathering additional data for
Gemview.
 GEMPRO messages count the number of reads and writes by GEMPRO via the
Profibus Connection.
5.6.3 Modbus

These statistics relate to the Modbus protocol.

Baud Rate. This is the Baud Rate at which Gemstart is trying to establish communications.
The following counters are Modbus define link statistics.
 C1 Bus Messages. The number of messages seen on the link to any address
 C2 CRC Error. The number of messages received with the correct length but the
wrong CRC
 C3 Bus Exception Errors. The number of invalid requests
 C4 Slave Messages. The number of messages to this address
 C5 Broadcast Messages. The number of messages to the broadcast address
 C9 Events. The number of messages that have been actioned

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5.6.4 Gembus

These statistics relate to the Gembus protocol.

Status gives a textual description of the protocol condition.
Broadcasts count s the number of broadcast messages received from the Host.
Group Command is the last command received from a broadcast command.
Scan Time is the time between the last two messages for this address.
Rx CRC Errors is a count of the number of messages received with the correct length but
which failed the CRC check,
Baud Rate. This is the Baud Rate at which Gemstart is trying to establish communications.
Host Link Number is the Link Number that the Host is transmitting to.
Lowest and Highest Address are the end points of the address range that Gemstart is
scanning. All addresses in this range are used.
PCM Version. This is the version of the software in the GE FANUC PCM card used to
communicate with Gemstart.

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5.7 Maintenance

This window contains information useful to the Maintenance engineer.

Some of the information in this window can be reset. The reset button is greyed if GEMPRO
does not have sufficient rights to reset Gemstart.
The Last Start frame has information about the last successful start. A start is defined as the
time from the contactor closing to the point where the current drops below 100%FLC.
 Peak Current. This is the highest phase current during the start. This is shown in
Amps and as a percentage of the motor Full Load Current
 Startup Time. This is the time from the contactor closing to the current dropping
below 100%FLC
 Thermal Content Used During Start. This is used to ensure that there is enough
thermal headroom to allow the next start. e.g. if the last start used 40% thermal
content then the next start will not be allowed until the thermal content has dropped
below 60%
The Trip Counters are also shown in the Faults & History window but can only be reset
from this window. Each counter can be individually reset.
The minimum and maximum current after startup allows the variation in motor current to
be monitored. Each value can be reset individually and both values are automatically reset
by a motor start.
Hours run is a cumulative total of the number of hours the motor is running. This counter
can go up to 65,535 hours. This counter increments while the motor is running in any mode
e.g. forward, reverse, speed 1, speed 2 etc.
Contactor Operations is a counter for each contactor. These counters can go up to
6,553,599.
The kWh Meter is also displayed in the Volts and Power window but can only be reset from
this window.

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5.8 Commissioning

The Inputs frame shows the state of all the physical inputs. Inputs 1 to 4 are local inputs fed
from a 24V supply from Gemstart. The interlock input and inputs 5 to 8 are multi voltage
inputs.
The Additional Inputs frame shows the state of the inputs on the additional Input module.
For all the inputs “0” indicates there are no volts on the input; “1” indicates that the
configured input voltage is present. N/O, N/C configuration does not affect the input display.
The Outputs frame shows the physical state of the 4 Gemstart outputs. “0” indicates output
relay open, “1” indicates output relay closed.
Gemstart Firmware. This frame shows version details about the firmware running in
Gemstart.
Update Gemstart Firmware. This button is the access point for updating the firmware in
Gemstart. The button is greyed unless GEMPRO is in Control. See the Special Operation
section before using this button.
User Language & Character set opens a form which allows you to read / write the
language definitions and character set definitions to / from Gemstart.
Show Diagnostics. Tick this option to show 32 words of debug information. This information
is for debugging and development use.

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5.8.1 User Language & Character Set

User Language
Gemstart 5 has the facility to display a user defined language. A language file can be read
from, or written into, Gemstart by GEMPRO via the front RS232 port. When reading the
language file from Gemstart the language read is the configured language. Language files
can be read from or written to Gemstart during normal running. I.e. motor protection and
System Control is not affected.

See section 9.5, to find out about reading, editing and writing language files.

Character Set
Gemstart 5 has the facility to use a user defined character set. A character set definition file
can be read from, or written into, Gemstart by GEMPRO via the front RS232 port. When
reading the character set file from Gemstart the character set read is the configured
character set. Character set files can be read from or written to Gemstart during normal
running. I.e. motor protection and System Control is not affected.

See section 9.6,Updating the Gemstart User Defined Character Set, to find out about
reading, editing and writing language files.

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6 Controlling Gemstart
6.1 Levels of Control
GEMPRO has 3 levels of control. “In Control”, “Requesting Control” and “Monitoring”.

6.1.1 Monitoring
Monitoring is the startup state of GEMPRO.

These icons are displayed in the Control Window and

the Button Bar when GEMPRO is in Monitoring Mode.

If Gemstart configuration requires a Security Key and a Security Key is not present then the
Monitoring Button is greyed.
In this state:
 The motor cannot be started or stopped
 The motor data can be monitored and, depending on the Gemstart configuration,
statistical data can be reset
 Configuration can be monitored but not changed

6.1.2 Requesting Control

Clicking the Monitoring button in the Control Window or the button bar requests control of
Gemstart.

These icons are displayed in the Control Window and

the Button Bar when GEMPRO is Requesting Control
from Gemstart.

If Gemstart is under Priority or Emergency control then Gemstart cannot grant control to
GEMPRO. GEMPRO stays in the Requesting Control mode.
In this state:
 The motor cannot be started or stopped
 The motor data can be monitored and, depending on the Gemstart configuration,
statistical data can be reset
 Configuration can be edited

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6.1.3 In Control
If Gemstart has no higher priority modes active then it gives control to GEMPRO. The
GEMPRO display changes to:

These icons are displayed in the Control Window and

the Button Bar when GEMPRO is In Control.

In this state:
The motor can be started or stopped.
The motor data can be monitored and statistical data can be reset.
Configuration can be edited.
6.1.4 Security Key
Each Gemstart contains a configuration item which defines if a Security Key must be present
to control that particular Gemstart.
If the Key is required but is not present then GEMPRO disables the ability to request control.

6.1.5 Start / Stop Commands

Once Gemstart is in Control Mode the Start and Stop Buttons allow the user to start and stop
the motor. The status bar indicates the status of the motor. This text is dependent on the
contactor type. In the above example the motor is stopped.
Start A is used for Start, Close, Forward, Star or Low Speed contactors.
Start B is used for Reverse or High Speed contactors.
Stop is used for Stop or Open.

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6.1.6 Reset Trips

The Reset Trips button resets any latched trips or alarms

present on Gemstart. If GEMPRO is not “In Control” then the
Gemstart configuration item “Monitor Mode Reset Actions”
defines if this button can reset latched trips and/or alarms.

6.1.7 Advanced Control

Ticking the Advanced Controls box in the Control window gives 2 additional options: Replace
PAMM and Test LCD & LED’s.

Replace PAMM is an advance operation and is covered in the Special Operation section of
this manual.

Test LCD & LED’s can be used to test the LCD and LED’s displays. This forces the LCD to
show the Company and product name, software reference and version and copyright details.
At the same time the 4 programmable LED’s go green then red. The LCD and LED’s then go
back to normal operation. This test does not affect control or protection and can be used at
any time.

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7 Configuring Gemstart
GEMPRO can be connected to Gemstart to edit the configuration “Online”. The configuration
in Gemstart is backed up in the Project Database which contains the details of every link and
address combination. I.e. link 0 address 0 to link 15 address 254.
If GEMPRO is not connected to Gemstarts then the Project Database can be edited
“Offline”.
Gemview 5 (an Engineering Workstation available separately) can also open the GEMPRO
Configuration Editor. This allows the Gemview user to edit Gemstart configuration using the
same user interface.

7.1 Project Database

GEMPRO maintains a Project Database. This database holds the configuration for all
Gemstart 5’s in a project. The database is a single file with a .gcf extension and holds the
configuration for 16 links (0-15) of 255 Gemstarts (addresses 0-254).
The Project Database can be used for a single Gemstart unit or an entire installation,
consisting of hundreds of Gemstart units using a unique link and address for each Gemstart.
The configuration data in the Project Database is automatically and continuously updated.
So even if the PC power is lost half way through editing all changes will have been saved to
disk.
Fig 1. GEMPRO Database structure.

GEMPRO

Edit Offline Edit

Configuration Database.gcf
(Online)
contains:
16 Links (0-15) of
255 Gemstarts (0- 254)
link link link link link
00 01 02 03
etc
Gemstart unit
add add add add add
with unique
00 00 00 00 00
Link Number
add add add add add
and Address.
01 01 01 01 01

add add add add add

02 02 02 02 02
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7.2 Offline Configuration

To avoid confusion this button is greyed if GEMPRO is connected to a Gemstart.

The Offline Edit function allows the user to create or edit a Project Database and configure
individual Gemstarts at any Link and Address. This allows an entire Project to be configured
before any Gemstarts have been commissioned.
During commissioning the configuration settings can then be transferred by:
 connecting GEMPRO to each Gemstart in turn
 requesting control and clicking the Edit Configuration button
 setting the address of the Gemstart (if it has not already been set)
 selecting the option to update Gemstart

7.3 Online Edit

or

This button is greyed if GEMPRO is not connected to a Gemstart. View Configuration is

displayed if GEMPRO is in monitor mode.
In Online edit GEMPRO makes changes to the configuration in Gemstart and the Project
Database simultaneously. Configuration cannot be changed if GEMPRO is in monitor mode.
If the connection to Gemstart is lost then the Online Edit window is automatically closed.

7.4 Levels of Control

Configuration data cannot be changed if Control has not been requested. Control can be
requested from the button bar or from the Gemstart Control window.

If you intend to change configuration settings, you must request control prior to opening the
editor.

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7.5 Configuration Window (Online and Offline)

The Configuration Windows for Offline and Online editing are very similar. The only visual
difference is the Gemstart Selection frame which is not present in Online Edit.

7.5.1 Gemstart Address is Not Set

If the Gemstart address is not set when you start the configuration editor you receive this
message:

When the Gemstart link and address are not set there is no corresponding entry in the
Project Database. It is recommended that you set the address, even if you are not using
the serial link. Once the address is set the Project Database maintains a backup of the
configuration.

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Press OK to edit the configuration without setting the address. You can set the address at
another time from the Communications window. With no address set only Gemstart is
updated with any changes. The Project Database does not have a copy of the
configuration.
Press Define Now to set the link and address now. NOTE: Once the address has been set
you cannot change it without help from an COMECA commissioning engineer.

Select the link and address and check it before

selecting OK.
Because the address has changed GEMPRO loses the
connection to Gemstart and then automatically
reconnect to the new address.

7.5.2 Configuration Data Mismatch

When the Online configuration editor is started it compares the configuration in Gemstart 5
with the configuration in the database. If the configuration is different then you are given an
option of how to resolve the situation:

 if the Gemstart has the right configuration

(e.g. Editing a Gemstart while running) but
the database (Project File) is wrong for this
Gemstart, the database must be updated :
click on “Update Disc”
 if the database has the correct configuration
but not the Gemstart (e.g. the gemstart
configuration has been changed by mistake),
the Gemstart must be updated: click on
“Update Gem”. Note: Gempro must be in
control mode to do this

 if the Gemstart configuration is right but must not change the database configuration
(e.g. the gemstart configuration has been changed for testing), it is possible to create
a new database (Project File) to keep track of this testing configuration without
modifying the “official” configuration : click on “New”
 if an other database must be used for this Gemstart (see File name on the Footer), it
is possible at this stage to directly open an existing database : click on “Open”. The
new configuration will be compared once again

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7.5.3 Gemstart Selection

When editing the configuration offline you can select and change which Gemstart
configuration you are editing. You do this by selecting the link number then the Gemstart
Address. To help you the link names and Gemstart Motor Tag are also displayed.

Online Editing automatically uses the link and address of the connected Gemstart.

7.5.4 Project Database (File Name)

The file name of the active Project Database is shown in brackets.

Project Name and Project Number are stored in the Project Database. This data is not
stored in Gemstart and is used for documentation purposes only.
Configuration Editor Language defines the language that is used for all GEMPRO texts.
The standard languages are English and French. Additional languages can be created by
editing the language definition files English.ced or Francais.ced to generate a new .ced file.
A “default” option is also available which ignores the language definition files.
New creates a new Project Database file. This database is initialised with default
configuration for every Gemstart address. A files explorer allows the file name and location
to be defined.
Open opens an existing Project Database. A file explorer allows the database to be located.
Link Names opens a window where the 16 links (0-15) can be give descriptive names.
Notice : for each New gcf file or for each Open gcf file, a copy with extension .bak is
created. In case of an handling error it is possible to get the original file back by deleting the
.gcf file in Windows Explorer and rename .bak file to .gcf file.

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7.5.5 Unit Summary

This frame contains a summary of information about the selected Gemstart.

Gemstart type can be changed in Offline edit but is automatically corrected when the online
configuration editor is started. It is important to set this correctly when defining a new
database as the Gemstart Type affects some of the configuration options available.
Contactor Type is a copy of the contactor configuration defined in the Fuse & Contactor
window.
Schematic is not used by Gemstart and is used for documentation purposes only.
Motor Tag is a copy of the tag configuration set in the Display Window.
Link Name is a copy of the name defined by the Link Names button above.
Project Database is a recall to the database file name.
Firmware Build and Issue is a definition of the firmware in the selected Gemstart. This is
automatically updated by the online configuration editor.

7.5.6 Configuration CRC’s

This information allows a quick validation of the configuration data. An unchanged CRC
(Cyclic Redundancy Check) method gives a very good indication that the configuration has
not changed.

The Overall CRC is a CRC of the all the Gemstart configuration. By recording the Overall
CRC’s for critical motors you can quickly audit the configuration settings by checking that
this CRC has not changed.

The factory settings CRC is based on Page 2 of the configuration printout (See Appendix A).
This is typically the same for a group of Gemstarts with the same basic configuration.

Commissioning settings is based on Page 3 of the configuration printout (See Appendix A).
Typically this covers the protection settings and is likely to be different for each motor and
application.

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7.5.7 Copy…

Copy… opens the “Copy From... To…” window and allows the configuration from one
address to be copied to several other addresses.
The Copy From Project Database can be changed with the Change Source Database
button.
The Copy To Project Database is fixed as the current Project Database.
Project Name is the name in each of the Project Databases.
A single Gemstart in the Copy From database can be selected and copied to multiple
addresses on a single link in the “Copy To” database. To copy to multiple Gemstarts you can
separate individual addresses with a comma or you can copy to a range of units by using a
dash. e.g. 1, 4, 6-9 copies to units 1, 4, 6, 7, 8 and 9.
The amount of configuration copied can be limited as follows:
 All Configuration copies all configuration options to the Copy To addresses. The
overall CRC will be the same on the Copy From and Copy To units
 Partial Configuration. The configuration copied is limited and defined by the
following selections. Ticking all the options is NOT the same as selecting “All
Configuration” as the Gemstart type, Ride Through, Auto Restart, Comms Control
Group, language and character set are not copied
 Schematic Name. The (Unit Summary) Schematic name is copied
 Page 2 Configuration. This copies the configuration included in the Page 2 CRC
(see Appendix A). This can be limited by disabling the User Text or Motor Tag texts.
Other options are not submitted to CRC.
 Page 3 Configuration. This copies the configuration included in the Page 3 CRC
(see Appendix A)

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7.5.8 Print
Print prints out the configuration detail for the selected Gemstart to the
selected printer.
A template Excel spreadsheet is installed with GEMPRO in the Export directory. As long as
you do not inset or delete any rows or columns you can edit this template to add your own
company logo if you wish.
The template spreadsheet is setup to print on A3. If you wish to print on A4 then edit the
template and change the File / Page Setup / Paper size to A4. You must repeat this change
on each of the 3 sheets.

7.5.9 Export
Export exports the configuration detail for the selected Gemstart to an
Microsoft Excel spreadsheet file.
A template Excel spreadsheet is installed with GEMPRO in the Export
directory. As long as you do not inset or delete any rows or columns you can edit this
template to add your own company logo if you wish.

7.5.10 Configuration Buttons

This area of the page contains 16 buttons that open up windows with specific areas of
configuration data.
The layout reproduces the separate areas of configuration for different parts of the circuit
and flows across the screen from the 3 phase supply through the fuses and contactor, phase
CT’s, earth fault CT to the motor and finally to the application “load”.
The motor protection is above and below the motor drawing and the application protection is
above and below the application drawing.
The motor and digital inputs are configured separately and a third button configures the 9
multi voltage inputs.
Communications configuration is connected by the two wire network and the PAMM by 3
wires.
Configuration of the display data is next to the LCD module drawing and GEMPRO
configuration next to the laptop.

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Each of the configuration buttons is explained in more detail below.
At the bottom of this area is the Configuration Editor program version information.

7.5.11 Status Bar

At the bottom of every configuration screen is a status bar with details about the connected
Gemstart and the connection to that Gemstart. Each section has the following information:
 The connection route (Standalone, Front Port or Gemview)
 The editing status (Monitoring, Editing Enabled, or Locked)
 The status the security key (No Key, Key Present)
 The Gemstart link number and address
 The Gemstart Motor Tag

7.6 Configuration Forms

There are 15 configuration forms and one Wizards form. The Wizards are not yet available.
7.6.1 Configuration Form Common Features
A number of features are common to each of the configuration forms.

One Form at a Time

While each configuration form is open you cannot access any of the GEMPRO windows or
other configuration editor forms.
In particular you cannot change the Control status if a configuration form is open. If you open
a configuration form and then decide to take control then you must close the form, request
control, and then open the configuration form again.
When each configuration form opens it is placed in the centre of the screen.
Invalid Configuration (Red Background)

If the configuration data for an item is invalid then the selection box is shown in red. This can
occur if the database has been corrupted or a new option has been selected with a newer
version of GEMPRO than the one you are using.
Non Default Setting (Yellow Background)

A configuration item that is not normally changed from its default is shown in yellow if the
default value is not selected. This is intended to highlight unusual configuration settings.

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Information Field (Grey Background)

Additional information is provided next to some configuration items. This additional

information cannot be modified here and is shown with a grey background.
No Permission or Not Relevant (Grey Foreground)

A configuration item that cannot be changed is shown with grey text. This can occur when a
configuration item is not relevant or you do not have permission to change the configuration.
In this example the speed 2 settings are now relevant and are greyed out.

Close Button

Each window has a close button which closes the form and allows access to the GEMPRO
windows or allows another Editor form to be opened.
CT, FLC and ALC dependencies

CT, FLC and ALC configuration are all defined in Amps. This allows incompatible options to
be set. E.g. CT = 1A, FLC=100A. Clearly a 1A CT would not be able to read 100A.
Some range checking is performed by Gemstart and incompatible configuration settings
generate Configuration Warnings. If you are editing online GEMPRO highlights this error by
displaying a warning message. The GEMPRO error message can be cancelled and the fault
remedied. Gemstart continues to show the error report until it is fixed.
The rules for the CT, FLC and ALC settings are:
 At 100%FLC the current on the internal Gemstart CT’s must be between 0.5A and
30A
 ALC must be less than or equal to FLC.
Speed 1 and Speed 2 Configuration

Some protection items can have different protection for each speed of a two speed motor.
These settings are shown regardless of the contactor type configured. If the contactor type is
not a two speed type then the speed 2 options are greyed.
Speed 1 settings are used for low speed and all non “2 speed” contactor types.

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Protection

…
For consistency the common protection features use the same format. Each item has the
following meaning:
Active. Tick to enable the protection.
Disabled in Startup. Tick to prevent the protection operating during the startup phase.
PreWarn at. Disable pre warning or select the pre warning percentage. The pre warning
percentage is a percentage of the fault level and does not take the protection time delay
into account. Selecting 100% produces a warning once the protection time delay has
started.
Severity. Select the action to take when the protection is triggered.
Warn. Self clearing message. Motor not stopped.
Alarm. Latched message. Motor not stopped.
Trip. Self clearing message. Motor is stopped. Motor can be started once fault clears.
LTrip. Latched message. Motor is stopped. Reset required before starting again.
Trip then Alarm. Latched message. Motor is stopped. Motor can be started once fault clears.

Digital Input Settings

Each input function can be configured to monitor 1 input. With this method of configuration it
is possible for several functions to monitor the same input.

For consistency all the input functions use the same format. Each item has the following
meaning:
 Source. This is the hardware input that the input function monitors. Two special
cases can be selected:
Disabled. The input function is always off. Changing the sense has no effect.
Active. The input function is always on. Changing the sense has no effect.
 Sense. Defines if the input is a normally open or a normally closed input. Defining an
input as normally closed effectively inverts the sense of the input
 Severity. Defines the action to be taken when the input becomes active.

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7.6.2 Supply Configuration Form

Contains the following setting:

 Motor Voltage
 Number of Phases
 Supply Frequency
 Monitored Voltage. This is the nominal voltage on the voltage monitoring input
 Monitored Phases. The phases from which the monitored volts is derived
 Inputs Supply Volatile. Indicates that Multi-Voltage Inputs are wired on the busbar
and lose their supply with the motor. In this case this option must be ticked.
 Supply Fail / Recovery levels. These are the points at which the Gemstart reports
Under Volts or recovers from Under Volts
 Ride Through time. At the end of the ride through time (up to 5s) the motor is
stopped if the supply has not recovered
 Auto Restart Maximum Dip Time. A supply recovery within this time will restart the
motor (if it was running when the supply was lost)
 Auto Restart Delay. The delay after the supply recovery before the motor is started.
Contains the following protection:
 Under / Over Voltage actions
 Phase Reversal actions

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7.6.3 Fuses and Contactors Configuration Form

Contains the following setting:

 Contactor Type. I.e. the type of motor being controlled
 Protection in case of external module loss (RTD or Input module)
 Contactor Feedback inputs A-D
 Outputs 1-4 functionality
 Fault1 Value/ Fault2 Value. Define the value of the Fault1/Fault2 parameter.
 Check Auxiliaries. If set and the contactor feedback is not as expected then a fault
is reported. E.g. Unexpected Open A. This setting is automatically updated when you
change the Contactor type. This setting is ignored if Follower Contactor is set
 Changeover Allowed. If set then Gemstart co-ordinates a Manual Mode request to
change from Forward to Reverse or vice versa. This setting is automatically updated
when you change the Contactor type
 Follower Contactor. If set and a contactor opens or closes, Gemstart follows this
operation as if it was ordered to start or stop. This setting is automatically updated
when you change the Contactor type
 Min Start Time. Gemstart stays in the startup phase for a minimum time
 Max STAR Time. Forces a Star/Delta starter to change to Delta after the defined
time
 Slow Down Time. Defines the minimum stop time between a
High Speed to Low Speed change
Forward to reverse or reverse to forward change
Delta to Star change

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 Contactor Settling Time. To chose regarding contactor opening time. It is not
advised to change the <0.5s value on other contactor type than MCCB.
Contains the following protection:
 Contactor Protection settings. If the current is over the contactor rating then the
contactor is held closed for the fuse blow time. If the fuse has not blown in the
defined time then the contactor is opened
7.6.4 Phase CT’s Configuration Form

Contains the following setting:

 CT Input Type. i.e. are external CT’s used and what secondary rating do they have
(1A or 5A)
 Number of CT’s. This is information if using internal CT’s. For external CT’s you
must confirm the number of CT’s used
 External CT’s Primary Rating. Not applicable if the Internal CT’s are selected
 Primary Turns Through CT’s. This is for both external and internal CT’s

7.6.5 Earth Fault Configuration Form

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Contains the following setting:
 Earth Fault Method. Earth fault input or residually calculated
 Earth Fault CT Primary Rating. Secondary is always 20mA.
Contains the following protection:
 Earth Fault settings and actions
7.6.6 Motor Protection Configuration Form

Contains the following setting:

 Motor FLC
Contains the following protection:
 Start Current settings and actions
 Start Time settings and actions
 Imbalance settings and actions
 Single Phasing settings and actions
 Starts In Hour settings and actions
 Speed Sense settings and actions

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7.6.7 Application Protection Configuration Form

Contains the following setting:

 ALC. The normal running current of the application

Contains the following protection:

 Under Current settings and actions
 Instant ALC settings and actions
 Continuous ALC settings and actions

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7.6.8 Thermal Protection Configuration Form

Contains the following setting:

 Curve Type for thermal overload protection. Options are:
Auto: based on the startup time and startup current protection settings
Gemstart 3: a copy of the curves used on Gemstart 3
Gemstart: the same protection curves as used on Gemstart 4
 Curve Speed for thermal overload protection. The higher the curve number the
slower the protection
 Hot / Cold Ratio. Adjusts the thermal protection to match a known number of starts
from cold and from hot
Contains the following protection:
 Thermal Overload based on heating effect of current
 Restart Inhibit. If the last successful start used x% thermal content then Restart
Inhibit does not allow a start until the thermal content drops below (99 – x)%.
Therefore the next start should not take thermal content over the 100% limit
 Thermal Reset Delay. A start is not allowed during a fixed delay after a thermal
overload trip
 PTC input. Configure the action which will occur if the PTC is hot. A short on the
PTC input will be shown as a Warning if the PTC protection is enabled
 RTD Inputs. Configure the fault and warn levels and the action which will occur if the
RTD inputs cross the fault level. A short or open circuit will be flagged as a warning if
the protection is enabled. RTD’s 1, 2 & 3 and/or RTD’s 4, 5 & 6 can be grouped
together and the highest temperature in the group used for protection. The fault
generated by the group protection can be defined as Group 1, Group 2, Bearings,
Stator, Low Speed or High Speed

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7.6.9 Power Protection Configuration Form

Contains the following setting:

 Motor Power Rating

Contains the following protection:

 Power Factor Low settings and actions
 Power Factor High settings and actions
 Under Power settings and actions
 Over Power settings and actions

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7.6.10 Manual Controls Configuration Form

Contains the following setting:

 Manual Select input. Enables manual control with the manual starts and process
stops
 Remote Select input. Selects between “Local Manual” (Manual Start A and Process
Stop A) and “Remote Manual” (Manual Start B and Process Stop B) if manual control
is enabled. If Remote Select is set to Active or Disabled then both sets of Start and
Stop are active in manual mode
 Inch Select input. If active Manual Start A and Manual Start B will stop the motor
when released
 Hard Stop input and severity. This stop is always enabled
 Process Stop A input. Only enabled in manual mode. See Remote Select
description above
 Process Stop B input. Only enabled in manual mode. See Remote Select
description above
 Manual Start A input and trigger mode. Only enabled in manual mode. See Remote
Select description above
 Manual Start B input and trigger mode. Only enabled in manual mode. See Remote
Select description above
 Emergency Start A input. Use with care. Activating this input will start the motor
regardless of status – even if a trip is present. Interlock is the only way to prevent this
starting
 Emergency Start B input. Use with care. Activating this input will start the motor
regardless of status – even if a trip is present. Interlock is the only way to prevent this
starting
 Test Mode Start input. If test position is active then this input closes the A contactor.
Releasing the input opens the contactor. In case of a system with 2 contactors,
activating the input again closes the B contactor

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7.6.11 Digital Inputs Configuration Form

Contains the following setting:

 Input Counter 1 input
 Input Counter 2 input
 Input Counter 3 input
 Reset inputs and actions
 Speed Sense input. Define here which input is used. Define in the Motor
Configuration Form the settings for this protection.

Contains the following protection:

 Interlock input and severity
 Isolator input and severity
 Overload Relay input and severity
 Thermistor Relay input and severity. This input has a build in delay of 300ms to
allow the external thermistor relay to power up and close its output
 ELCB Relay input and severity
 Device Status input and severity. Typically used with an MCCB
 Test Position input and severity. Indicates that the chassis has been disconnected
from the motor
 User Text 1 input and severity. The text for this input is defined in the Display
Configuration Form
 User Text 2 input and severity. The text for this input is defined in the Display
Configuration Form

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7.6.12 Multi Voltage Inputs Configuration Form

Contains the following setting:

 Interlock Input voltage and ride through time
 Input 5 voltage and ride through time
 Input 6 voltage and ride through time
 Input 7 voltage and ride through time
 Input 8 voltage and ride through time
 Input 9 voltage and ride through time
 Input 10 voltage and ride through time
 Input 11 voltage and ride through time
 Input 12 voltage and ride through time

Define the Voltage Level of each input then consider how much dip time you want to ignore.
The Ride Through Time allows the Gemstart to ignore short dips in supply. Setting the ride
through time to 20ms results in the Gemstart not reporting the loss of signal for 20ms. If the
voltage recovers before this time then no change of state is reported. This ride through time
only affects loss of voltage; it does not apply to the return of voltage which is always
detected within 3ms.

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7.6.13 PAMM Configuration Form

Contains the following setting:

 PAMM Missing at Power On action. At power on Gemstart reads the configuration
data and statistical data from the PAMM. Note that if the PAMM is present the PAMM
data is always used. If the PAMM is not present Gemstart can use the internal copy
of the PAMM data.
Select “Use Backup Data” if you are not using a PAMM or you want
Gemstart 5 to power up using its internal copy of the PAMM data when the
PAMM cannot be detected. This has the advantage of ensuring Gemstart is
always available after a Power On but may cause problems if you move
chassis and the new PAMM is not detected
Select “Wait for PAMM” before you move a chassis, or, if you want a very
secure system which only operates when the PAMM is connected and
working. With “Wait For PAMM” selected Gemstart does not operate without a
PAMM present at power on

Contains the following protection:

 PAMM Missing after Power On action. After Power On Gemstart keeps the data in
the PAMM up to date by continuously updating the device. A backup copy of the data
is also maintained in Gemstart. If the connection to the PAMM is lost you have a
choice of actions: Warn; Alarm; Trip and Latched Trip. We recommend “Warn” as this
lets you know there is a problem but does not prevent normal operations

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7.6.14 Communications Configuration Form

Contains the following setting:

 Protocol Selection
 Baud Rate. Can be set to Auto. Profibus always Auto bauds
 Timeout Time. The time since the last valid message before the link fail action is
taken
 Link Fail Action. The action to take after the timeout time
 Priority Commands Enabled. All protocols have a method of sending Priority
commands. Priority Mode commands can override Manual Mode and GEMPRO
Mode. This feature can be disabled by selecting No
 Profibus Emergency Start Enabled. Profibus can send an Emergency Start. This
command starts the motor even if there is a trip present. This feature can be disabled
by selecting No

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 Serial Link Number and Address. This can be set with the Define Address button if
not already set. Once the address is set it cannot be changed. This ensures
maximum serial link security
 Operator Reset command actions. A bit received from the serial link master
 Supervisor Reset command actions. A bit received from the serial link master
 Status Bit 1 definition. A bit sent to the serial link master
 Status Bit 2 definition. A bit sent to the serial link master
 Group 10 Data definitions. Five words of data sent to the serial link master
 Profibus Current/Power multiplier. For small power applications, allows to multiply
the current and/or power by 100 before sending to Profibus link

7.6.15 Display Configuration Form

Contains the following setting:

 Language. The language used by Gemstart for the LCD display. The ability to
download the user defined language is not yet available
 Character Set. The ability to download the user defined character set is not yet
available
 Line 1 Display. The line 1 display is a single item of data which is double the height
and half the number of characters of lines 2 and 3

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 Line 2 Display. Two or three items of information
 Line 3 Display. Two or three items of information
 Motor Tag Text. A motor ID displayed on the LCD and on GEMPRO
 User Text 1 message. Configurable text message linked to an input
 User Text 2 message. Configurable text message linked to an input
 LED 2, 3, 4 and 5 operation. Define the function and colour

The default LED Function setting is Auto. Gemstart 5.1 has a different set of “Auto” functions
to Gemstart 5.3 and 5.4. When GEMPRO is connected to Gemstart, Gemstart automatically
updates the function configuration “Auto” settings depending on the Gemstart used. For 5.3
and 5.4 the Auto settings are Running, Stopped, Fault and Serial Mode. For 5.1 the Auto
settings are Input 1, Input 2, Input 3 and Input 4.
Because Gemstart can change the Auto Function configuration (for example by changing a
Gemstart 5.1 to a Gemstart 5.3 or 5.4) the CRC for page 2 will also change. If you are using
the Page 2 CRC as a method of configuration validation then you should set the LED
functions explicitly. Auto colour does not necessary have to be set explicitly.
The default colour option is Auto. For some functions the Auto option has 3 colours. In most
cases the Auto option is what you would expect. If not you can override the colours used.
The first colour listed is the Inactive state, the second the active state. E.g. if you pick
Off/Green for the Running LED then the LED is OFF while the motor is stopped and Green
while the motor is running.

7.6.16 GEMPRO Configuration Form

Contains the following setting:

 Security Key Required. If set then control and configuration changes are not allowed
without the key. You cannot change this configuration unless the key is present
 Front Port Configuration Allowed. If not set then the configuration can only be
changed via the Profibus / Modbus / Gembus serial link. You can only change this
configuration if you are editing via the rear port
 Monitor Mode Reset actions. These are the groups that are reset if GEMPRO is in
monitor mode when reset is sent

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8 Gemstart Wizards
The wizards are intended to quickly configure Gemstart at each stage of the chassis life.
Namely:

1. Manufacturing - to allow the chassis manufacturer to define the chassis

components.
2. Commissioning - to allow the commissioning engineers to set the motor protection.
3. Implementation - to allow the customer to set the plant protection to suit the
process.

An additional wizard, “Reset Configuration”, is provided to allow configuration to be put in a

known condition before starting the Chassis Wizard.

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8.1 Reset Configuration

The Reset Configuration wizard loads the default configuration settings into Gemstart. This
puts all the configuration settings, except the address, to the default setting. This allows a
known configuration to be used as a starting point for the Chassis Wizard.

When you select the Reset Configuration button the following confirmation form is shown.
Check that you are resetting the unit that you want to reset and then press OK.

Following is a summary of the main configuration settings after they have been reset:

 DOL-E Contactor with N/C contactor feedback on input 1

 Primary CT’s (Internal CT’s)
 FLC set to “Same as CT”
 Earth Fault Configured for an 8A external CT and to “latched trip” at 8A.
 Phase Reversal protection On
 Single Phase protection On
 Start Current protection On at 800%FLC
 Start Time protection On at 10s
 Thermal Overload protection On with curve 15 (7.6s at 600%FLC)
 All other motor protection is off
 All power protection is off
 All application protection is off
 The Interlock input is configured to trip
 All other input functions are disabled

The Reset Configuration wizard can be used in online or offline editing.

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8.2 Chassis Wizard

The Chassis Wizard defines the electrical characteristics of the components in the chassis.
This information is set by the chassis manufacturer before supplying the chassis.

The following settings are defined by the Chassis Wizard:

 Gemstart Type
 Contactor Type
 CT Type
 Primary Turns
 Number of CT’s
 CT Rating
 EF Method
 EF Rating
 Voltage Settings
Note: The FLC is not defined by this wizard. The motor should not be started until the
FLC has been set.
The Chassis Wizard can be used in online or offline editing.

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8.2.1 How to complete the Chassis Wizard
To complete the Chassis Wizard you must check and update the data on each of the tabs
shown. Work from the left tab to right tab to update the data. Some tabs will appear or
disappear as you change the data. This is the wizard assisting you by hiding irrelevant tabs
or revealing tabs that are now relevant.

You can move around all the tabs by using the “Back” or “Next” buttons or by clicking on the
desired tab.

When you “Close” the Chassis Wizard no changes to the Gemstart configuration are made.
Changes are only made when you select “Apply Changes” on the Summary page. Any
settings you select in the Chassis Wizard are remembered until you close GEMPRO. So you
can close the Chassis Wizard and come back to it later if you wish.

Once you reach the Summary page you have completed all the information required by the
Chassis Wizard. A summary of all the relevant data is shown. If you are happy you can
implement all the changes by clicking on “Apply Changes”.

8.2.2 Instructions
The first tab of the Chassis Wizard gives brief instructions on how to complete the Wizard.

8.2.3 Contactor Type

Select the correct options on this page. Remember no changes are made to the
configuration until you select “Apply Changes” on the summary page.

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8.2.4 Phase CTs

This page is hidden if you selected Gemstart 5.1.

For Gemstarts 5.3 and 5.4 you have to define how the CTs are wired. If you have external
CTs then define the secondary rating of the CTs as 1A or 5A.

8.2.5 CT Primary Rating

This page is hidden unless you have external CTs.

Define the number of external CTs present and the Primary rating of the external CTs.

8.2.6 Earth Fault Method

This page is only available for Gemstart 5.4.

Gemstart 5.4 is the only Gemstart that provides an option for residually summing the 3 CTs
to calculate the earth fault current.

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8.2.7 Earth Fault CT Rating

If you have an Earth Fault CT then define the primary rating of the CT here. Gemstart Earth
Fault CT’s must have a secondary rating of 20mA. Two Core balance Current Transformers
(CBCTs) are available from COMECA: 8A:20mA and 16A:20mA.
8.2.8 Supply

Gemstarts 5.3 and 5.4 can read voltage. The motor voltage and the method of connection to
the motor supply are defined here. The Monitored Voltage could be the secondary voltage of
the transformer connected to the motor supply or the single phase voltage of a 3 phase
system. E.g. 240V is the single phase voltage of a 415V, 3 phase system.

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8.2.9 Summary
Once you have finished entering data to the Wizard you can review the data on the summary
page. If there are any errors they can be corrected by returning to the relevant tab. Once you
are happy that the data entered is correct you can modify the Gemstart configuration by
clicking the “Apply Change” button. You can now close the wizard.

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8.3 Motor Wizard

The Motor Wizard is used during commissioning for new systems before the first start of the
motor. This wizard sets the protection to the known limits of the motor. If some motor data is
unknown then reasonable default values are suggested.

The following settings are updated by the Motor Wizard.

 Motor Power Rating
 FLC
 Contactor & Fuse Rating

The 3 items above are updated in the Gemstart configuration immediately (if you quit the
Wizard, these changes remain). The following items are only updated once you click the
“Apply Changes” button on the summary page.
 Start Current
 Start Time
 Thermal Overload

To make full use of the Motor Wizard you must have the following motor information. If you
do not have all this information then reasonable default values are suggested by the wizard.
 Motor Power Rating
 Motor FLC
 Motor Acceleration Time

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 Startup Inrush Current
 Stall Current
 Stall withstand time from cold
 Stall withstand time from hot

After running the Motor Wizard Gemstart will provide accurate motor protection. The first
start of the motor can now be performed.
The Motor Wizard can be used in online or offline editing.

8.3.1 How to complete the Motor Wizard

To complete the Motor Wizard you must check and update the data on each of the tabs
shown. Work from the left tab to right tab. You can move around all the tabs by using the
“Back” or “Next” buttons or by clicking on the desired tab.
Changes made on the Basic Ratings page are automatically updated in Gemstart
immediately (if you quit the Wizard, these changes remain). These ratings must be correctly
defined before moving to the other tabs in the Motor Wizard.
When you “Close” the Motor Wizard no changes to the Motor Protection configuration are
made. Changes are only made when you select “Apply Changes” on the Summary page or
change the Basic Ratings.
Once you reach the Summary page you have completed all the information required by the
Motor Wizard. A summary of all the relevant data is shown. If you are happy you can
implement all the changes by clicking on “Apply Changes”.

8.3.2 Instructions
The first tab of the Motor Wizard gives brief instructions on how to complete the Wizard.

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8.3.3 Basic Ratings
Enter the motor rating and full load current. These ratings should be available on the motor
nameplate.

To protect the contactor from breaking currents above its rating you need to enter the rating
of the contactor. For AC4 systems this has to be at least 10 times the motor FLC. For AC3
systems this contactor must be rated to 6 times the FLC. If the current is above the contactor
rating Gemstart will keep the contactor closed long enough for the fuse to blow. Enter the
maximum time that the fuse should take to blow when the current is above the contactor
rating. If the fuse does not blow within this time the Gemstart will attempt to open the
contactor.

Unlike other settings in the Wizards, changes to this Motor Wizard page are updated in
Gemstart immediately (if you quit the Wizard, these changes remain). All other Wizard
changes are not passed to Gemstart until the “Apply Changes” button is selected.

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8.3.4 Motor Details
The following data can be found on the motor data sheet or rating plate. If the information is
not available then use your experience to enter a reasonable value or use the suggestion
shown to the side.

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8.3.5 Motor Protection
Based on the data entered on the Basic Ratings and Motor Details page a new Start Current
and Time are suggested. This page shows you the existing configuration in the top half of
the page. The lower half shows the new suggestion. You can adjust these suggestions if you
wish. The suggestions are updated (and any adjustments lost) every time a change is made
to the Basic Ratings or Motor Details page.

The Start Current suggestion is the greater of:

 half way between the start inrush and the stall current
 one setting higher than the inrush current

The Start Time suggestion is the greater of:

 half way between the acceleration time and the stall withstand time from hot
 one setting higher than the acceleration time

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8.3.6 Overload Protection

Based on the data entered on the Basic Ratings and Motor Details page a new Overload
Curve is suggested. This page shows you the existing configuration in the top half of the
page. The lower half shows the new suggestion. You can adjust the suggestions if you wish.
The suggestions are updated every time a change is made to the Basic Ratings or Motor
Details page.

The Curve suggestion is the curve that allows the indicated number of starts from cold where
each start is at the inrush current for the acceleration time.

The Hot/Cold Ratio suggestion is set to unknown if the stall withstand time from hot is 0. For
non zero times the ratio is calculated as the Withstand Time From Hot / Withstand time From

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Cold * 100%. E.g. 2 / 10 * 100% = 20%

More information about the Overload Protection can be found in Volume 2, section 3.5.15,
Thermal Protection / Overload.

8.3.7 Summary
Once you have finished entering data to the Wizard you can review the data on the summary
page. If there are any errors they can be corrected by returning to the relevant tab. Once you
are happy that the data entered is correct you can tick the relevant Accept boxes. Clicking
the “Apply Change” button will modify the configuration in Gemstart for the protection item
suggestions that have been accepted. You can now close the wizard.

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8.4 Protection Wizard

The Protection Wizard can be used after a successful start to tighten the protection of key
items and give maximum detection of changes in motor operation.

Note: The FLC must be correctly set and a successful motor start performed before
using this Wizard.

This Wizard is only available if Gemstart is connected and a successful start has been
completed since Gemstart was last powered up. For two speed motors Gemstart keeps
separate records for each of the speeds. This allows the Protection Wizard to analyse the
data for low and high speed at the same time.

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8.4.1 How to complete the Protection Wizard
To complete the Protection Wizard you should check the data about the last start and ensure
it is typical of a normal motor start. You can then check the suggestions listed on the
Summary page. If necessary you can see more information about the changes that will be
made. You can move around all the tabs by using the “Back” or “Next” buttons or by clicking
on the desired tab.

On each of the Protection Pages the existing protection settings are shown greyed in the top
half of the page. The bottom half of each page shows the suggested settings. The
suggestions can be adjusted as required. If you click “refresh the motor data” then the
suggestions are updated and any adjustments are lost.

When you “Close” the Motor Wizard no changes to the configuration are made. Changes are
only made when you select “Apply Changes” on the Summary page.

On the Summary page you will find a summary of the protection suggestions. If you do not
want to update one of the protection items you can clear the Accept box for that protection
item. You can implement the accepted changes by clicking on “Apply Changes”.

The following protection settings are updated by the Protection Wizard:

 Start Current protection
 Start Time protection
 Thermal Overload protection
 ALC
 Under Current protection
 Instant ALC protection
 PF Low/High protection
 Under/Over Power protection
 Auto Restart

The Protection Wizard can be used in online editing only.

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8.4.2 Motor Data
The motor data from the last motor start is shown in the left
hand column of the Protection Wizard. For two speed
motors you can see the data for the last start of each speed
by clicking the relevant tab at the top of the column.

At the top there are 3 items that you can update

 The Protection Wizard margin defines how much of

a margin is added to the run time data to define the
new protection levels. A good starting point is 20%.
If you get nuisance trips you will have to increase
this value. This affects all the protection suggestions
 The Starts from Cold and Hot allows you to tell the
Wizard how many starts you want the wizard to
allow the motor to make. This only affects the
overload protection
 The FLC, Curve at last Start and Power Rating are
automatically picked up from the configuration data

The rest of the data in this column is information about the

motor during or since the last start. This data is
automatically updated on starting the Protection Wizard but
is not updated again unless you click the “Refresh Motor
Data” button.

Pressing the “Refresh Motor Data” button will update the

motor information with the latest information available from
Gemstart. All suggestions are then automatically updated.

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8.4.3 Summary
This page presents a summary of the Protection Wizard suggestions. The accept box
indicates which protection items you wish to update. Remove the tick to remove the
protection item from the Wizard Update. Selecting Apply changes will update the protection
items that have been accepted.

The ALC suggestion is always accepted and cannot be disabled because the Under Current
and Instant ALC protection suggestions are based on the new ALC suggestion. However
you can adjust the suggested ALC setting if required.

It is possible to turn off the protection by clearing the Active flag and clicking Apply Changes.

You can return to any of the protection suggestions by clicking the relevant tab or clicking
the “Review Settings” button next to the relevant protection item.

Once the changes have been applied the Wizard automatically clears the Accept flags.

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8.4.4 Instructions
The first tab of the Motor Wizard gives brief instructions on how to complete the Wizard.

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8.4.5 Motor Protection
The Protection Wizard suggests settings for the start current and start time.

The start current suggestion is the Wizard Margin above the Start Peak Current. E.g. 20% of
600% start peak = 120%. 600% + 120% = 720%.

The start time suggestion is the Wizard Margin above the startup time. E.g. 20% of 2s is 0.4s
2s + 0.4s = 2.4s. The next option above this is 3s.

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8.4.6 Thermal Protection
A new overload curve and hot cold ratio is suggested.

The Overload Curve suggestion aims to allow the desired number of starts from cold to take
the thermal content to 100%. The wizard margin is taken into account.

E.g. If the last start used 10% and the margin is 20% then 5 starts from cold would use,
(10% + 20% of 10%) * 5 = 60%
Gemstart then adjusts the curve to speed up the protection. The ratio between curves is
1.259. So changing from curve 15 to curve 13 would alter the total thermal content from 60%
to 95% (i.e. 0.60 * 1.259 * 1.259).

The Hot Cold Ratio is calculated by dividing the number of starts from Hot by the starts from
cold and converting to a percentage. E.g. 1/5 * 100% = 20%

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8.4.7 Application Protection
This page shows the suggestions for ALC, Under Current and Instant ALC.

The ALC suggestion is half way between the minimum and maximum current after starting.

The undercurrent suggestion is the margin below the minimum current. E.g. Minimum
current was 7.0A which is 7/7.5 * 100%ALC = 93% ALC. Minus 20% for the margin =
73%ALC. The first setting below 73% is 70%.

The under current time is not changed by the wizard.

The instant ALC is the margin above the maximum current. E.g. Maximum was 8.0A = 8/7.5
* 100%ALC = 107%ALC. Add 20% for the margin = 127% The first setting above is 130%.

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8.4.8 Power Factor Protection
The Power Factor Low and Power Factor High protection suggestions are shown here.

The Power Factor High suggestion is the max power factor + the margin. E.g. 0.70 + 0.20 =
0.90

The Power Factor Low suggestion is the min power factor - the margin. E.g. 0.50 - 0.20 =
0.30

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8.4.9 Power Protection
The Power Protection page displays the suggestions for Under and Over Power protection.

The Over Power suggestion is based on the maximum power plus the margin percent. E.g.
80% + 20% = 100%.

The under Power suggestion is based on the minimum power minus the margin percent.
E.g. 70% - 20% = 50%.

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8.4.10 Auto Restart
The Auto restart page prompts you to update the Auto restart settings. The wizard does not
modify the Auto Restart settings but they are here because this is a good time to consider
how you want Auto restart to operate.

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9 Special Operations
9.1 Updating Gemstart Firmware
From time to time new releases of Gemstart firmware are issued which contain new features
or fault fixes. If your system requires the new feature or is suffering from a fault that has
been fixed then you can update the firmware in Gemstart from GEMPRO.
This operation can only be performed by taking Gemstart out of service for about 1 minute.
As every new firmware version is upward compatible it is now impossible
to update a Gemstart5 with an older version than the one already present
in it. In case it is necessary, please contact us.

Obtain the necessary permission to work on Gemstart. You need to stop the motor. You will
not need to power cycle Gemstart or remove it from the service position.
Start GEMPRO and connect to Gemstart. Open the Control Gemstart window.

Click the monitoring button to take control. Stop the motor. Close the window.
Stay in control and open the Commissioning Window.

At the bottom of the window are the details about the firmware already loaded in Gemstart.
In this example the firmware is 5450 H23. The CRC is provided for verification.
Click Update Gemstart Firmware and a warning message is shown.

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Click OK.
Click Load Binary File.

Select the new version to be downloaded. The file name should be in the format
XXXXYYY_crc_ZZZZ.bin. XXXX specifies the firmware reference. For Gemstart 5 this
should be 5450. YYY specifies the firmware issue. This is a letter followed by a 2 digit
number. A major release increments the letter and resets the number to 01. Minor releases
increment the number. Take a note of the file name to allow the download to be verified.
Click Open.

If the file name differs from the structure given above, an error message will show up.
If the selected file is an older version than the one in Gemstart5, an warning message
concerning upward compatibility will be displayed. The update will be forbidden.
Check the file name in the header is correct. This is the last chance to abort programming.
To abort from here click the X at the top right.

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To program Gemstart click Program.

Programming progress is shown on the status bar. If power to Gemstart or the PC was lost
during the programming stage then go to the next section “recovering a partially updated
Gemstart”.

WARNING : it is important to wait for the CRC to update before closing the
“Commissioning” window. Otherwise, GEMPRO may not refresh correctly its
data.

Once programming has completed the Finished Programming box appears. Click OK.

After a few seconds the version details and CRC should be updated in the Commissioning
window. Verify these against the original file name.

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9.2 Recovering a Partially Updated Gemstart

If power to Gemstart or the PC is lost during the programming period then Gemstart may be
in a part programmed state. In this state GEMPRO cannot communicate with Gemstart. You
must complete the update using the Gemstart 5 Flash Loader.

Close GEMPRO and start Programs / GEMPRO / Gemstart 5 Flash Loader

Select the com port used to connect to Gemstart and click Load Binary File.
Navigate to the new firmware file, select the file and click Open.

Flash loader now displays the file name in the header and has enabled the other two
buttons. Click Enter Flash Mode.

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The status bar message changes. Click program.

The status bar shows progress.

When complete the following message appears.

Click OK and Flash Loader automatically closes.

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9.3 Adding a new language to GEMPRO

All text messages in GEMPRO can be replaced with alternative language text.

As standard GEMPRO comes with an option for English and French. The texts for these
languages are defined in the files G5English.ced and G5French.ced. These files can be
found in the GEMPRO installation directory.
You can modify the English and French texts by modifying these files but any changes are
overwritten when you install a new version of GEMPRO.
The default language option uses English text that is built into GEMPRO and cannot be
modified.
To create a new language file take a copy of either the G5English or G5French files and
rename it in the form G5xxxxxx.ced. e.g. G5AltEng.ced. The next time GEMPRO is started it
detects the new file and gives the new set of options:

To customise the file you must edit the new file in a simple text editor such as Notepad.
This file is made up of several sections and each section has a set of keywords. The section
names are in square brackets. The keywords are before the equals sign ‘=’ on separate
lines. Do not change the section names or the keywords. The text after the equals sign ‘=’ is
the text to be translated.

The first section in the file is called Language and the first keyword is ThisLanguage.
ThisLanguage defines the name of the language shown in the language options box. If you
change this to “New Language” and save…

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…then when you next start GEMPRO and select a language you will have a new option.

The next section in the file is called [Common]. This section contains keywords that are used
throughout GEMPRO. The text after the equals sign ‘=’ should be translated.
Some strings contain “%c” or “%d”. e.g. “Operations of %c (Hundreds)” This marks where a
character or number is placed. Your translation should contain the same place markers.
Some texts are split across two lines. The point where the text is spit is marked with “\n”.
E.g. Fuses And\nContactor.

The remaining sections contain text for the windows (forms) in GEMPRO. As you translate
each section you should check the relevant window to ensure the translated text fits.
Not all forms are available under normal operations.
[Language] File identification
[Common] Common texts
[ConfigForm] Main configuration form
[SupplyForm] Configuration form
[FusesAndContactor] Configuration form
[PhaseCTs] Configuration form
[EarthFault] Configuration form
[MotorProtection] Configuration form
[ApplicationProtection] Configuration form
[ManualControls] Configuration form
[DigitalInputs] Configuration form
[MVIConfiguration] Multi voltage inputs configuration form
[RawHexEditor] Not normally available
[PAMM] Configuration form
[Communications] Configuration form
[Thermal] Configuration form
[Power] Configuration form
[Display] Configuration form
[GEMPRO] Configuration form
[Wizards] Configuration form
[AddressChange] Define Address form
[EditLinks] Link names form

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[CopyDialogue] Copy… form
[Printing] Text added to the printouts
[VoltageAndPower] Voltage and Power form
[TimersAndCounters] Timers and Counters form
[CommsLost] Comms Lost pop up box
[ChangeComms] GEMPRO Connection form
[FaultsAndHistory] Faults and History form
[Buttons] Button bar hint texts
[ControlForm] Control Gemstart form
[CurrentsForm] Currents form
[TemperatureForm] Thermal and Temperature forms
[CommissioningForm] Commissioning form
[FlashLoader] Update Gemstart Firmware form
[LastStart] Maintenance form
[GEMPROMain] GEMPRO startup form
[OfflineEdit] Additional text for Offline Edit form
[PrivateForm] Not normally available
[SerialForm] Serial Link form
[Status] Status bar texts
[FaultDecodes] Fault texts

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9.4 Replacing a Faulty PAMM

Due to the very low complexity of the PAMM device it is very rare for a PAMM to fail in
service. If a PAMM Missing fault is reported then first test the PAMM wiring before deciding
to replace the PAMM.
Warning : this operation requires to work inside the fixed part of the cubicle. Only
qualified people to electrical risks can proceed to the PAMM replacement

The method for replacing the PAMM depends on the configuration of the PAMM Missing at
Power On item.

Wait for Missing PAMM

If PAMM Missing at Power On is set to Wait then Gemstart will not operate until a working
PAMM is connected.
If the new PAMM connected is blank then the backup data held in Gemstart is down loaded
to the new PAMM. It is therefore important to use a blank PAMM in this situation. PAMM’s
are supplied blank by COMECA.
If the new PAMM connected was previously used with Gemstart
5 the PAMM will contain valid configuration. Gemstart will use
the configuration data in the PAMM. This will over write the data
backup in Gemstart.

In this case, update is made from PAMM to Gemstart.

Use Backup Data

If PAMM Missing at Power On is set to Use Backup then Gemstart will startup with the on
board data.
Start GEMPRO and open the Control Gemstart window.
Click on the Monitoring button to take control of Gemstart. Stop the motor. Tick the
Advanced Control box.

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Clicking on Replace PAMM puts Gemstart in a Fatal Error condition and reports “Fatal Error,
Power Down & Replace PAMM” on the LCD unit. GEMPRO loses the connection to
Gemstart.
Power down Gemstart, replace the PAMM with a used or blank PAMM.
When Gemstart powers back up it automatically overwrites the data in the PAMM with the
data backed up internally.
In this case, update is made from Gemstart to PAMM.

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9.5 Updating the Gemstart User Defined Language

9.5.1 Read Language from Gemstart

GEMPRO can read the translatable messages in Gemstart and create a file with the name of
the language and a .glf (Gemstart Language File) extension e.g. English.glf. This file is in the
same format as an .ini file with section and item definitions. GEMPRO reads all of the
translatable messages from Gemstart and places each message in the correct section of the
.glf file.
In “Commissioning”, click “User Language & Character Set” then “Read Active Language
from Gemstart to File”.

The language file that is read from Gemstart is the language that Gemstart is configured to
display. This allows any of the built in languages or the previously written User Defined
language to be read.

Once all of the translatable text has been downloaded you are prompted to save the data.
The default file name (language name . glf) is the name of the language downloaded.

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9.5.2 Gemstart Language File (*.glf) Format
The language file is split into sections which divide up the different kinds of messages. The
following sections are in the Gemstart Language File.
[Language] the name of the language
[Fault Text] all the fault messages
[Severity] warn, alarm, trip and latched trip
[Motor Status] e.g. running, available, tripped etc
[Modes] e.g. auto, manual etc
[Bottom Line Status] e.g. Overload trip in ###s
[Motor Data] displayed on lines 1, 2 and 3
[Additional Messages] text added to a later Gemstart that GEMPRO
does not know about.
Within each section there are item names that match the English text. E.g.
NO_FAULTS=”No Faults”
UNKNOWN_FAULT=”Fault Code ### Unknown§”
The text before the “=” is the item name and must not be changed. The text after the “=” is
the language text enclosed in quotes. There are two characters that have a special meaning.
These characters are:
§ This character (Alt+0167) appears in the fault text section. When displayed
this character is replaced with the severity text e.g. Warn, Alarm etc Note that
the default severity text contains a space character.
# This character is used in fault messages to mark where more specific data is
placed. E.g. “Failed to Close A” and “Failed to Close B” use the same
message but have a # to mark where the A or B is placed.
# is also used in the other sections to mark the position of variable data such
as current or voltage. The number of #’s must match the built in language
messages. The order that the data is displayed cannot be changed.

9.5.3 Editing the Gemstart Language File (*.glf)

The best way to create new language file is to read one of the build in languages and then
edit the language file to create the new language. The file is a simple text file and can be
edited with Windows Notepad.

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9.5.4 Gemstart Built In Character Set
The following proportionally spaced character set is used by Gemstart and any character
can be entered into the language file. If your keyboard does not support a particular
character you can enter it with the Alt key as follows. Turn NumLock on. Hold down the Alt
key and, on the number keypad, type the 4 digit code from the table below. E.g. to get “½”
hold Alt and type 0189 on the number keypad.
Note: This feature does not work with the numbers on the top row of the
keyboard. You must use the number keypad.
Code 0 1 2 3 4 5 6 7 8 9

0030 ! " # $ % & '

0040 ( ) * + , - . / 0 1
0050 2 3 4 5 6 7 8 9 : ;
0060 < = > ? @ A B C D E
0070 F G H I J K L M N O
0080 P Q R S T U V W X Y
0090 Z [ \ ] ^ _ ` a b c
0100 d e f g h i j k l m
0110 n o p q r s t u v w
0120 x y z { | } ~
0130

0140 Œ Ž
0150 ˜ š œ ž Ÿ
0160 ¡ §
0170 ± ² ³
0180 µ · ¸ ¹ º ¼ ½
0190 ¾ ¿ À Á Â Ã Ä Å Æ Ç
0200 È É Ê Ë Ì Í Î Ï Ð Ñ
0210 Ò Ó Ô Õ Ö × Ø Ù Ú Û
0220 Ü Ý Þ ß à á â ã ä å
0230 æ ç è é ê ë ì í î ï
0240 ð ñ ò ó ô õ ö ÷ ø ù
0250 ú û ü ý þ ÿ
9.5.5 Editing Limitations
When editing any message the number of # characters in the message must not be
changed. The # is used to mark where data is inserted in a message and if the wrong
number of # characters exist then the displayed data will be wrong.
The fault text messages can be up to 50 characters long INCLUDING the severity text. So if
the longest severity text (e.g. Alarm) is 5 characters then the faults string should be limited to
45 characters. Fault messages wider than the LCD (about 25-30 characters depending on
the characters used) will be scrolled to display the whole text.
The Bottom Line Status messages and the Motor Data messages are not scrolled. Check
that the message fits on the LCD. The limit is about 25-30 characters depending on the
characters used.
If a message definition is not present in the .glf file then Gemstart will use the built in English
message.

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9.5.6 Write Language to Gemstart

GEMPRO can copy text from a .glf file into Gemstart. This text will then be available for use
on Gemstart as the User Defined language.
Take Control and click “Commissioning” then “User Langage & Character Set” then Write
Language File to Gemstart”.

Choose glf file to tansfer.

GEMPRO displays the progress during the transfer.

Finally, in the Editor, click “Display” and choose “User Defined Language” to enable the new
language.

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9.6 Updating the Gemstart User Defined Character Set

9.6.1 Read Character Set from Gemstart
GEMPRO can read the character set definition in Gemstart and create a file with a .gcs
(Gemstart Character Set) extension e.g. UserCharSet.gcs. This file is in the same format as
an .ini file with section and item definitions. GEMPRO reads all of the character definitions
from Gemstart and places each character in its own section of the .gcs file.
Click “Commissioning” then “User Language & Character Set” then “Read Active Character
Set from Gemstart to File”.

The character set that is read from Gemstart is the character set that Gemstart is configured
to display. This allows the built in or the previously written User Defined Character Set to be
read.

Once all of the character set has been downloaded you are prompted to save the data. The
default file name is UserCharSet.gcs.

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9.6.2 Gemstart Character Set File (*.gcs) Format
The character set file is split into a section for each character.

Within each section there is a definition for one character. E.g.

[Char_49]
Default='1'
Char_49_0=" * "
Char_49_1=" ** "
Char_49_2="* * "
Char_49_3=" * "
Char_49_4=" * "
Char_49_5=" * "
Char_49_6="*****"
Char_49_7=" "

The section name [in square brackets] defines the ASCII character number. The default item
shows the default ASCII character for this character number. The Default item is only
provided by GEMPRO for information and is not required.

The text before the “=” is the item name and must not be changed. The text after the “=”
and between the quotes is the character definition. A space character is a blank pixel. A “*”
character turns the pixel on. Each character definition has 8 rows, 0 to 7, and can be up to
16 pixels wide.

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9.6.3 Editing the Gemstart Character Set (*.gcs)
The best way to create new character set file is to read one from Gemstart and then edit the
file to create the new character set. The file is a simple text file and can be edited with
Windows Notepad.

9.6.4 Editing Limitations

Every vertical column in a character definition must have at least one pixel set. i.e It is not
possible to define a character with a blank column in the middle.
The maximum character width is 16 pixels.

9.6.5 Write Character Set to Gemstart

GEMPRO can copy character definitions from a .gcs file into Gemstart. The User Character
Set will then be available for use on Gemstart as the User Defined Character Set.
Take Control and click “Commissioning” then “User Language & Character Set” then “Write
Character Set File to Gemstart.

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Choose gcs file containing the modified character set.

GEMPRO shows the progress of the transfer.

Finally, go to the Editor Configuration, click on “Display” and choose “User Defined
Character Set” to enable the new character set.

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10 Appendix A – Configuration Printout

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11 Index
Adding a new language to GEMPRO .... 98 FLC ............................ 6, 21, 25, 37, 52, 57
Administrator Rights .............................. 12 French .................................................. 12
ALC....................................... 6, 25, 52, 58 Fuses and Contactors ........................... 55
Application ............................................ 58 Gembus .......................................... 36, 67
Button Bar ................................. 22, 40, 41 GEMPRO Configuration ........................ 67
COM Port .............................................. 18 GEMPRO Main Screen ......................... 21
Commands ..................................... 41, 65 Gemstart Address ........................... 45, 47
Commissioning3, 21, 24, 38, 48, 93, 95, Gemstart Selection ......................... 45, 47
100
Grey Background ................................ 52
Common Data ....................................... 34
Grey Foreground................................. 52
Common Features ................................ 51
Installation............................... 3, 4, 12, 15
Communications ................. 46, 50, 65, 99
Key .................... 12, 16, 17, 21, 40, 41, 67
Configuration CRC’s ............................. 48
Language ........... 12, 16, 22, 47, 66, 98, 99
Configuration Data Mismatch ................ 46
Maintenance ......................................... 37
Configuration Forms.............................. 51
Manual Controls .................................... 61
Configuration Window ........................... 45
Modbus ..................................... 30, 35, 67
Configuring Gemstart ...................... 11, 43
Monitoring ..........................11, 24, 40, 101
Connecting to Gemstart .................. 11, 18
Motor21, 26, 47, 48, 49, 51, 53, 54, 57,
Control10, 21, 22, 27, 38, 40, 41, 42, 44, 60, 62, 67
51, 93, 100, 101
Multi Voltage Inputs .............................. 63
Controlling Gemstart ....................... 11, 40
Offline Configuration ............................. 44
Copy ..................................................... 49
Online Edit ................................ 23, 44, 45
Counters ............................................... 27
Operating System ............................... 12
CT ..............................6, 25, 50, 52, 56, 57
PAMM .................. 42, 50, 64, 99, 101, 102
Currents ................................................ 25
Power21, 24, 26, 37, 60, 64, 99, 100, 101,
Digital Input ......................................... 53 102
Digital Inputs ......................................... 62 Print ..................................................... 50
Display .................................................. 66 Printing ................................................ 12
Earth Fault ...................................... 56, 57 Profibus ................... 24, 30, 34, 35, 65, 67
English .................................................. 12 Project Database ..... 43, 44, 45, 46, 47, 49
Event History ........................................ 31 Protection ............... 53, 56, 57, 58, 59, 60
Export ................................................... 50 Recovering a Partially Updated Gemstart
.......................................................... 96
Exporting ............................................. 12
Red Background ................................. 51
Fault List ............................................... 29
Replacing a Faulty PAMM ................... 101
Faults and History ................................. 29
Requesting Control ............................... 40
Flash Loader ................................... 96, 97

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Reset Trips ............................... 11, 29, 42 Thermal .........................25, 27, 37, 59, 99
Security ........ 12, 16, 17, 21, 23, 40, 41, 67 Timer and Counters .............................. 27
Serial Link...................21, 24, 34, 66, 100 Timers................................................... 27
Special Operations ................................ 93 Trip History ........................................... 30
Speed 1 ................................................ 52 Unit Summary ................................. 48, 49
Speed 2 ................................................ 52 Updating Gemstart Firmware ................ 93
Start Menu ...................................... 16, 17 Using GEMPRO .................................... 17
Starting GEMPRO ................................. 18 Voltage and Power................................ 26
Status .................... 34, 36, 51, 62, 66, 100 Wizards........................................... 51, 99
Supply ................................................... 54 Yellow Background............................. 51
System Requirements ........................... 12

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 COMECA Equipements Basse Tension

Route de Givry – ZI La Garenne – F 71880 Châtenoy-le-Royal France Tel.: +33 (0)3 85 98 22 00 Fax+33 (0)3 85 98 22 01

Internet: www.comeca-group.com