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Thermon GENESIS - User Manual

Thermon GENESIS
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GENESIS CONTROLLER
CONTROL AND MONITORING SYSTEM
Installation, Operation & Maintenance Guide
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Thermon GENESIS Specifications

General IconGeneral
Sensor TypeRTD
OutputRelay, SSR
EnclosureNEMA 4X
Power Supply100-240 VAC
HousingPolycarbonate
Operating Temperature-40°C to 60°C (-40°F to 140°F)
CertificationscULus

Summary

PRODUCT WARRANTY INFORMATION

Section 1: Genesis Controller Introduction And Overview

Section 2: Panel Inspection, Field Connections And Internal Wiring

Recommended Visual Inspection Procedures

Visual checks for panel integrity, dust, corrosion, and mechanical parts.

Wiring and Connections Survey

Inspecting electrical connections for temperature, corrosion, and wiring integrity.

Control System Operation Check

Energizing the panel and checking heat trace circuits for proper cycling.

Heat Trace and Insulation Installation

Installing heat trace and insulation according to project details and guides.

Power Distribution Wiring and Breakers

Selecting and installing power wiring and circuit breakers suitable for the service.

Panel Wiring

Connecting field wiring to the panel and ensuring proper termination and testing.

Section 3: The Genesis Controller System-Overview

Genesis Controller Modules Overview

Overview of HMI, DCM, DTM, and IOM modules and their functions.

The Genesis Controller HMI Screens

Details on navigating and using the Human Machine Interface screens.

Section 4: Genesis Controller Control Options and Examples

Line Sensing Control

Control method using RTDs directly sensing pipe-wall surface for temperature.

Ambient Sensing Options

Control methods using ambient temperature sensing for heat trace operation.

Control Method: On-Off with Soft Start

On-Off control utilizing cycle omission to ramp up power gradually.

Section 5: Genesis Controller Testing and Start-Up

Troubleshooting Tips

Guidance for correcting start-up issues and clearing alarm/trip events.

Section 6: Operation & Maintenance of the Genesis Controller Control & Monitoring System

Maintenance

Preventive maintenance procedures including inspection, testing, and cleaning.

Maintenance Schedule Recommendation

Recommended schedule for servicing the heat tracing control and monitoring panel.

QUICK START GUIDE

Overview Screen

Displays status of circuits on the dashboard interface.

Circuit Dashboard

Detailed view of a circuit's parameters and setpoints.

Hamburger Menu Navigation

Accessing main menu for navigation and adjustments via touch interface.

Global Settings

Adjusting system-wide variables like language and temperature units.

Circuit Settings

Adjusting specific variables for individual control circuits.

SPECIFICATION GUIDE

GENESIS CONTROLLER SPECIFICATIONS

Environmental, operating, and component specifications for the controller.

GENESIS CONTROLLER COMPONENT APPROVALS

Certifications and listings for hazardous and non-hazardous locations.

HMI (HUMAN MACHINE INTERFACE)

HMI SPECIFICATIONS

Technical data including voltage, consumption, IP rating, and dimensions.

HMI PRODUCT FEATURES

Key features like IP66 rating, multi-language, touch screen, and display.

DCM (DISTRIBUTED CONTROL MODULE)

DCM FEATURES

Key capabilities like ambient operation, relay types, and test functions.

DCM COMPONENT SPECIFICATIONS

Circuit capacity, temperature ranges, and power terminal details.

DCM CONNECTION DIAGRAM

Diagram showing connection points for transformers and relays.

DTM (DISTRIBUTED TEMPERATURE MODULE)

DTM PRODUCT FEATURES

Features like RTD sensor input, DIN rail mount, and conformal coating.

DTM COMPONENT SPECIFICATIONS

Ambient temperature ranges, terminal connections, and capacity.

DTM CONNECTION DIAGRAM

Diagram illustrating RTD inputs and CANBus connector.

IOM (INPUT OUTPUT MODULE)

IOM PRODUCT FEATURES

Features like configurable channels, DIN rail mount, and conformal coating.

IOM COMPONENT SPECIFICATIONS

Ambient temperature ranges, terminal connections, and weight.

IOM CONNECTION DIAGRAM

Diagram showing input/output channels and alarm relay outputs.

GENESIS NETWORK

GENESIS NETWORK COMPONENTS

Overview of server, gateway, bridge, and third-party controllers.

DCS (DISTRIBUTED CONTROL SYSTEMS) COMMUNICATIONS

Communication interface between Genesis Controller and plant DCS via Ethernet.

PRODUCT REFERENCE LEGEND

Genesis Controller Series

Codes for selecting controller series based on RTD inputs.

Enclosure Type

Codes for selecting enclosure material and IP rating.

Trace Heater Control Relays

Codes for selecting relay types (Solid State, Mechanical).

Enclosure Size

Codes for selecting physical dimensions of the enclosure.

Appendix C: Troubleshooting Tips For Reliable Electrical Heat Trace Performance

High Temperature Reading;Alarm

Possible causes and recommended solutions for high temperature alarms.

Low Temperature Reading;Alarm

Possible causes and recommended solutions for low temperature alarms.

RTD Sensor Alarm

Causes and solutions for RTD sensor reading alarms and communication issues.

Communications Alarm

Causes and solutions for communication failures between modules.

Circuit Fault Alarm

Causes and solutions for circuit fault conditions like wiring or breaker issues.

High Current Readings;Alarms

Possible causes and solutions for high current readings or alarms.

Low Current Readings;Alarms

Possible causes and solutions for low current readings or alarms.

High Ground Current Alarm

Causes and solutions for high ground current alarms and leakage issues.

Appendix D: Genesis Controller DCS Communication Guide

Part 1: Genesis Controller Modbus Communication Protocols

Details on Modbus TCP/IP frame format and exception codes.

Part 2: Modbus Memory Map for the Genesis Controller

Description of memory map for accessing controller data via Modbus.