R P.O. Box 292 Sunnybank Brisbane Australia.
© 2000 - All rights reserved PROPRIETARY No part of the Innotech Genesis II System’s hardware, software, firmware or documentation may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, without prior written permission of Innotech Control Systems Australia.
Installation Instructions for Innotech Genesis Systems TABLE OF CONTENTS SECTION/PARAGRAPH PAGE SECTION 1-PRELIMINARY INFORMATION ............................................................. 1-1 1-1. INTRODUCTION. .................................................................................................. 1-1 1-1.1. SYSTEMS COVERED BY THIS MANUAL. ............................................ 1-1 1-1.2. SCOPE OF THIS TECHNICAL MANUAL. ............................................. 1-2 1-2.
Installation Instructions for Innotech Genesis Systems TABLE OF CONTENTS – (Continued) SECTION/PARAGRAPH PAGE 3-3.2. GENESIS II MID POINTS CONTROLLER. ............................................ 3-10 3-3.2.1. Power Input. .................................................................................... 3-11 3-3.2.2. Digital Inputs. .................................................................................. 3-11 3-3.2.3. Digital Outputs. .........................................................
Installation Instructions for Innotech Genesis Systems TABLE OF CONTENTS – (Continued) SECTION/PARAGRAPH PAGE 4-1.2.4.1. Voltage Checks. ......................................................................... 4-14 4-1.2.4.2. Current Checks. ......................................................................... 4-15 4-1.2.4.3. Resistance Checks. ..................................................................... 4-17 4-1.2.5. Checking Analogue Output Wiring. ........................................
Installation Instructions for Innotech Genesis Systems TABLE OF CONTENTS – (Continued) SECTION/PARAGRAPH PAGE A-4.2.9. Genesis II Non-Isolated Comms. ................................................... A-14 A-4.2.9.1. Hazardous Earth-Connections. ................................................ A-16 A-4.2.9.2. Use of GENII POLY SWITCH Boards. .................................. A-18 A-4.2.10. Genesis II Isolated Comms. ............................................................ A-20 A-4.2.11.
Installation Instructions for Innotech Genesis Systems LIST OF ILLUSTRATIONS – (Continued) FIGURE 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. A-1. A-2. A-3. A-4. A-5. A-6. A-7. A-8. A-9. A-10. A-11. A-12. A-13. A-14. A-15. A-16. A-17. A-18. A-19. A-20. A-21. A-22. A-23. A-24. A-25. A-26. A-27. PAGE Checking Power Input. ............................................................................................... 4-4 Checking Digital Input Wiring. ............................................................
Installation Instructions for Innotech Genesis Systems LIST OF TABLES TABLE 2-1. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 4-1. 4-2. 4-3. 4-4. vi PAGE REM Resource Counts. .............................................................................................. 2-10 Nominal Resistance for Wire Sizes at 20°C. ............................................................. 3-2 Genesis II Digital Controller Digital Inputs. ........................
Installation Instructions for Innotech Genesis Systems SECTION 1- PRELIMINARY INFORMATION 1-1. INTRODUCTION. This manual is intended to provide qualified technical personnel with complete and easy-tofollow instructions for installation, checkout and commissioning of the various devices in the Innotech Genesis Systems.
Installation Instructions for Innotech Genesis Systems The purpose of this manual is to provide clear and complete instructions for all phases of the installation of the units that comprise your Genesis System.
Installation Instructions for Innotech Genesis Systems Individual systems may include hardware items that are not represented in this manual. In such cases, data sheets for the items are included in Appendix B. The contents of Appendix B are different for each system configuration. Appendix B in your technical manual contains only data sheets, if any, that are applicable to your system. 1-2. SPECIAL CONSIDERATIONS.
Installation Instructions for Innotech Genesis Systems • Computer-Generated Materials List – the Materials List is also provided at the time of hardware delivery. The list is printed out from the configuration software as is the wiring diagram described above. The Materials List shows all the items of hardware required for the specific application. • For non-Innotech equipment, gather the manufacturer’s installation-related data such as schematics, wiring diagrams, dimension diagrams, etc.
Installation Instructions for Innotech Genesis Systems SECTION 2- MECHANICAL INSTALLATION 2-1. INTRODUCTION. This section of the manual contains instructions and related data to facilitate the installation of components of the Genesis I or Genesis II System. Because of the physical similarities of the two systems, instructions contained in this section apply equally to the Genesis I and Genesis II Systems, except where otherwise noted.
Installation Instructions for Innotech Genesis Systems plastic base has eight mounting holes; each hole is 4mm in diameter. Not all of the eight holes are required for mounting, providing the unit is securely installed. There are four slots in the bottom circuit board (motherboard) - two slots at each end. These slots facilitate the clamping of the plastic lid to the motherboard.
Installation Instructions for Innotech Genesis Systems 2-2.1.2. Genesis I Digital Controller. The Genesis I Digital Controller is used only in Genesis I Systems. The main physical difference between the Genesis I and Genesis II controllers is that the Genesis I Digital Controller does not contain a display or operator’s keyboard as does the Genesis II controller.
Installation Instructions for Innotech Genesis Systems DIN Rail Mounted 75 57 R GENESIS II DIGITAL INPUT MODULE 155 ALL DIMENSIONS ARE IN MILLIMETRES Figure 2-4. Typical Local Expansion Module. 2-2.2.2. Remote Expansion Modules. The term: Remote Expansion Module (REM) is the collective nomenclature applied to the several types of units used to configure the hardware to the customer’s requirements.
Installation Instructions for Innotech Genesis Systems The system imposes restrictions on the total number and types of REMs that can be used with a controller. These requirements are explained in Paragraph 2-4.1. DIN Rail Mounted 75 1 2 3 57 R GEN II AI REM 155 ALL DIMENSIONS ARE IN MILLIMETRES A BC D E F GH I J K L MNO Figure 2-5. Typical Remote Expansion Module. 2-2.2.2.1. Remote Module Interface.
Installation Instructions for Innotech Genesis Systems DIN Rail Mounted 75 57 R GENESIS II REMOTE MODULE INTERFACE 155 ALL DIMENSIONS ARE IN MILLIMETRES Figure 2-6. GENII RMI Remote Module Interface. 2-2.2.2.2. Control Station Module. The GENII CS REM Control Station Module (Figure 2-7) is housed in a switch plate that mounts in a standard electrical wall plate at a remote location.
Installation Instructions for Innotech Genesis Systems 2-2.2.2.3. Multipoint Module. The GENII MP REM Multipoint Module is a DIN Rail-mounted device that provides input/output expansion capability for the associated Genesis II Digital Controller or GENII MPC. It is designed to be located at a remote location. The GENII MP REM is enclosed in a square case made of flameresistant Astrene M650 IR plastic. It is identical in appearance and dimensions to the GENII MPC (Figure 2-3).
Installation Instructions for Innotech Genesis Systems 45mm Slotted Cable Duct Panel Size 600 X 900mm GENESIS II A.I.M. See Note 45mm Slotted Cable Duct See Note D.I.M. D.I.M. D.O.M. D.O.M. 45mm Slotted Cable Duct 45mm Slotted Cable Duct R See Note Digital Controller Power Transformer 45mm Slotted Cable Duct Auxiliary Power Transformer Terminal Strip NOTE: 65mm Space Between Duct and Terminals in These Areas. Standard Power Point (Outlet) Figure 2-8. Typical Enclosure Layout. 2-3.1. DIN RAILS.
Installation Instructions for Innotech Genesis Systems 25 15 35 Mounting Slot 18 X 5.2 ALL DIMENSIONS ARE IN MILLIMETRES Figure 2-9. DIN Rail Dimensions. 2-3.2. INSTALLATION GUIDELINES. To ensure continued reliable operation of the Genesis II System, the following installation guidelines should be observed: • The Genesis II Digital Controller should be installed in a position that provides easy access to the front panel and sufficient room for power, and input/output cabling.
Installation Instructions for Innotech Genesis Systems 2-4. DIFFERENCE DATA. This paragraph contains difference data unique to installation of the Genesis I Digital Controller, the GENII MPC, Genesis II REMs and related devices. Installation Instructions provided in Paragraph 2-3 are applicable except where stated otherwise. 2-4.1. REM LIMITATIONS. The following limitations apply to the installation of REMs: • • LEMs and REMs cannot be used with the same Digital Controller or GENII MPC.
Installation Instructions for Innotech Genesis Systems 2-4.2. TYPICAL INSTALLATION. Figure 2-11 shows an example of a typical installation using REMs.
Installation Instructions for Innotech Genesis Systems 2-4.3. ADDITIONAL INSTALLATION GUIDELINES. For installation of the Genesis II Digital Controller or GENII MPC system with REMs, observe the applicable installation guidelines in Paragraph 2-3.
Installation Instructions for Innotech Genesis Systems SECTION 3- ELECTRICAL INSTALLATION 3-1. INTRODUCTION. This section of the manual contains instructions and related data to facilitate the electrical installation of the Genesis I or Genesis II System. Because of the electrical similarities of the two systems, instructions contained in this section apply equally to the Genesis I and Genesis II Systems, except where otherwise noted.
Installation Instructions for Innotech Genesis Systems NOTE If any data presented in this manual disagrees with information in the applicable instruction manual, information in the manufacturer’s instruction manual takes precedence. Customers are encouraged to contact Innotech Control Systems Australia for further information or clarification of information presented herein. Use the address or phone/fax number shown on the cover of this instruction manual.
Installation Instructions for Innotech Genesis Systems automatically produces a wiring diagram and materials list for the specific application. The wiring diagram and materials list can be easily printed out and used for reference. Figure 3-1 shows a typical computer-generated wiring diagram. A printout of the wiring diagram and materials list is usually provided at the time of hardware delivery.
Installation Instructions for Innotech Genesis Systems 3-3.1. GENESIS II DIGITAL CONTROLLER. Figure 3-2 shows the input/output connection groups for the Genesis II Digital Controller. The controller uses Phoenix type plug-in terminal strips located around the controller’s perimeter. Both single row and double row terminals are used. Terminals are grouped by function as follows: • • • • • • • • • Power Input(Paragraph 3-3.1.1) Digital Inputs (Paragraph 3-3.1.2) Digital Outputs (Paragraph 3-3.1.
Installation Instructions for Innotech Genesis Systems 3-3.1.1. Power Input. The Genesis II Digital Controller power requirements are: • 24Vac ±10%, 50/60Hz at 1.0A, or • 24Vdc ±10%, at 0.75A (Factory Modification is Required) For 24Vac supply voltages, a safety transformer with a nominal rating of 30VA must be used for the Digital Controller. The transformer must be in compliance with EN60742, designed for 100% duty and fused in compliance with local safety regulations.
Installation Instructions for Innotech Genesis Systems Table 3-2. Genesis II Digital Controller Digital Inputs. TERMINAL SIGNAL POSITIVE SIDE TERMINAL SIGNAL NEGATIVE SIDE 3 DI1+ 4 DI1− 5 DI2+ 6 DI2− 7 DI3+ 8 DI3− 9 DI4+ 10 DI4− 11 DI5+ 12 DI5− 13 DI6+ 14 DI6− 15 DI7+ 16 DI7− 17 DI8+ 18 DI8− 3-3.1.3. Digital Outputs. Each of the Genesis II Digital Controller’s eight digital output channels (Terminals 41–64) consists of a single-pole, double-throw (SPDT) relay.
Installation Instructions for Innotech Genesis Systems 3-3.1.4. Analogue Inputs. The Genesis II Digital Controller’s eight analogue input channels (Terminals 21-36) allow the direct interface of various analogue inputs, such as Thermistor, 0-10Vdc, 0-5Vdc and 4-20mA signals. Each analogue input channel is configured to the type of input by the use of Analogue Input Signal Conditioners (AISCs). These are small plug inserts installed during system commissioning (Section 4).
Installation Instructions for Innotech Genesis Systems 3-3.1.5. Analogue Outputs. Sixteen analogue output channels are provided. Each channel can be configured, through the Genesis II Configuration Software, to operate in either the Variable Mode or the Heat Valve Mode. In the Variable Mode, the output is a voltage-analogue signal varying from 0 to +10 Volts with a maximum current rating of 5mA.
Installation Instructions for Innotech Genesis Systems Table 3-5. Genesis II Digital Controller Analogue Outputs. TERMINAL SIGNAL TERMINAL SIGNAL 65 AO1 77 AO5 66 AO2 78 AO6 67 AO3 79 AO7 68 AO4 80 AO8 69 Common 81 Common 70 Common 82 Common 71 Common 83 Common 72 Common 84 Common 73 AO9 85 AO13 74 AO10 86 AO14 75 AO11 87 AO15 76 AO12 88 AO16 3-3.1.6. Pulse Counter Inputs.
Installation Instructions for Innotech Genesis Systems ribbon cable at the LEM/REM Connector. The individual REMs are connected to the RMI by means of an RS 485 Comms cabling arrangement as explained elsewhere in this section. 3-3.2. GENESIS II MID POINTS CONTROLLER. Figure 3-4 shows the input/output connection groups for the Genesis II Mid Points Controller (MPC). The MPC uses terminal strips located around the controller’s perimeter.
Installation Instructions for Innotech Genesis Systems NOTE Because much of the MPC’s input/output connection information is similar to that of the Genesis II Digital Controller, the following paragraphs make frequent reference to related paragraphs in the Genesis II Digital Controller section. Therefore, readers should familiarise themselves with the types of data contained in Paragraph 3-3.1 and its subparagraphs before reading further. 3-3.2.1. Power Input.
Installation Instructions for Innotech Genesis Systems NOTE Two terminals, located between the Digital and Analogue Input terminal groups (Figure 3-4), are provided for terminating cable screens. 3-3.2.5. Analogue Outputs. The Genesis II MPC’s analogue output wiring information is similar to that of the Genesis II Digital Controller (refer to Paragraph 33.1.5), with the following exceptions: • The MPC only uses four analogue output channels: AO1 through AO4.
Installation Instructions for Innotech Genesis Systems P IG c a V 4 2 D IN R E W O A T S T U P L A EG R C S O L N L L S T P IN E U SM T U P IN /R M E E N O 5 6 4 3 2 1 5 2 4 3 2 0 1 9 8 7 8 2 7 0 9 4 3 1 4 C 1 0 3 9 8 7 6 5 0 4 9 8 7 3 6 C R O T 9 5 6 3 0 8 7 5 2 4 1 8 2 1 3 2 0 9 7 6 4 4 3 6 0 8 9 5 8 7 6 9 5 4 7 3 2 1 0 9 1 AL T IG D SO P T U O L T N A P T U ER U G M O C 5 8 4 R S EC N O C 3 2 S R O T 24Vac POWER 1 2 LEM ANALOGUE INPUTS CONNECTOR DIGITAL INPUTS SCREENS 3 4 5 6 7 8 9 10 11 12 13 14 1
Installation Instructions for Innotech Genesis Systems • • • • • • • • GENII AIM AISC – Analogue Input Module AISC GENII DO5 – D05 Digital AISC GENII I05 – 0-5mA Passive AISC GENII I20 – 0-20mA Passive AISC GENII TH1 – Thermistor, Type 1 AISC GENII TH9 – Thermistor, Type 9 AISC GENII V05 – 0-5Vdc AISC GENII V10 – 0-10Vdc AISC 3-3.3.3. Analogue Outputs.
Installation Instructions for Innotech Genesis Systems Each type of LEM provides four additional signal channels for the controller. The Genesis II Digital Controller can use up to eight LEMs, in any combination, thus achieving 32 extra signal channels. There are critical requirements for the physical placement of the LEMs; refer to Section 2. When installing the LEM cable between the controller and the LEMs, observe the following precautions: • • The LEM cable should be run external of cable ducts.
Installation Instructions for Innotech Genesis Systems or to terminate cable screens. Terminal 2 is the GND terminal for the analogue signal to the controller; the cable screen and the screens from the four local analogue inputs should terminate at this point. Terminal 3 connects to the appropriate + analogue input terminal on the controller. The exact input terminal on the controller is indicated on the computergenerated wiring diagram. Analogue input terminals for the AIM are listed in Table 3-9.
Installation Instructions for Innotech Genesis Systems CAUTION LOOP POWERED 4-20MA INPUTS MUST NOT BE USED WITH THE GEN II ANALOGUE INPUT MODULE. 3-4.1.2. DIM Digital Input Modules. Each DIM (Figure 3-8) provides an expansion capability of four additional digital input channels. The DIM does not have power terminals since operating power is supplied from the controller by way of the LEM cable. LEM CABLE CONNECTOR GENESIS II DIGITAL INPUT MODULE DIGITAL INPUTS Figure 3-8. Digital Input Module.
Installation Instructions for Innotech Genesis Systems 3-4.1.3. DOM Digital Output Modules. Each DOM (Figure 3-8) provides an additional four channels of digital outputs, each having voltage-free SPDT output relay contacts. The relay contacts are rated at 240Vac, 2A. POWER INPUT 24Vac 0Vac LEM CABLE CONNECTOR GENESIS II DIGITAL OUTPUT MODULE DIGITAL OUTPUTS Figure 3-9. Digital Output Module. A 24Vac supply is required to power the module and can be taken from the transformer serving the controller.
Installation Instructions for Innotech Genesis Systems 3-4.2. REMOTE EXPANSION MODULES.
Installation Instructions for Innotech Genesis Systems 3-4.2.2. RS485 Comms Connections. The RS485 Comms link between the RMI and the other LEMs is designed to allow reliable communications over long distances in electrically adverse signal conditions.
Installation Instructions for Innotech Genesis Systems Figure 3-10 shows how to connect a two-cable Comms network to a module. If the module has only one RS485 Comms cable connected to it, the cable screen must be connected to S1. If two Comms cables are fitted, the screen of the second cable must be connected to the S2 terminal. Screens must not be connected to each other. S1 CABLE #1 + _ S2 CABLE #2 Figure 3-10. RS485 Comms Cable Connections. 3-4.2.3. RMI Remote Module Interface.
Installation Instructions for Innotech Genesis Systems TX RX REM CABLE CONNECTOR GENESIS II REMOTE MODULE INTERFACE COMMS EARTH CONNECTION RS485 COMMS CONNECTIONS END OF CABLE JUMPER Figure 3-11. RMI Remote Module Interface. 3-4.2.4. AI REM Analogue Input Module. The AI REM (Figure 3-12) is powered by 24Vac ±10% at 4VA maximum. It provides for six analogue inputs from field equipment. Each analogue input circuit has a socket for fitting an AISC, which defines the input type and range selection.
Installation Instructions for Innotech Genesis Systems Edition 011100 3-23
Installation Instructions for Innotech Genesis Systems Table 3-12. AI REM Analogue Input Signal Connections. TERMINAL SIGNAL TERMINAL ACTIVE SIGNAL REFERENCE A AI1+ B AI1− C AI2+ D AI2− E AI3+ F AI3− G AI4+ H AI4− I AI5+ J AI5− K AI6+ L AI6− SCREEN Common Screens 3-4.2.5. AO REM Analogue Output Module. The AO REM (Figure 3-13) provides up to five analogue outputs.
Installation Instructions for Innotech Genesis Systems 3-4.2.6. IDI REM Opto Isolated Digital Input Module. The IDI REM provides five isolated digital inputs to sense signals from field equipment. The IDI REM is similar, in appearance and terminal layout, to the AO REM. Digital input terminals are located at the bottom of the module; input signal connections are listed in Table 3-14. Table 3-14. IDI REM Digital Input Signal Connections.
Installation Instructions for Innotech Genesis Systems Table 3-16. DO REM Relay Output Signal Connections. TERMINAL SIGNAL NORMALLY OPEN (NO) TERMINAL SIGNAL COMMON (C) A Relay 1 B Relay 1 C Relay 2 D Relay 2 E Relay 3 F Relay 3 G Relay 4 H Relay 4 I Relay 5 J Relay 5 3-4.2.9. CS REM Control Station Module. The CS REM mounts into a standard electrical wallplate. The only connections to the CS module are 24Vdc power and the RS485 Comms link.
Installation Instructions for Innotech Genesis Systems L N E C I O DI 1 POWER P- C+ I O DI 2 C I O DI 3 C I O C DI 4 I O DI 5 DIGITAL OUTPUTS COMMS P+ C C- SHLD DIGITAL INPUTS +DI#1- +DI#2- +DI#3- +DI#4- SENSOR TH1 TH2 SHLD MODULE VIEWED FROM THE REAR Figure 3-15. MP REM Multipoint Module. POWER and DIGITAL OUTPUTS terminals are arranged across the top edge of the module’s main circuit board.
Installation Instructions for Innotech Genesis Systems The group of five terminals at the lower left of the module serves two separate functions. The two terminals on the left of the group (P+ and P-) provide a 12Vdc source for digital input signals (Figure 3-16). The three terminals on the right side of the group are the COMMS cable connections: • C+ = RS 485 (+) Signal • C- = RS 485 (-) Signal • SHLD = Comms cable shield The MP REM accepts up to four isolated, switched-contact, digital inputs.
Installation Instructions for Innotech Genesis Systems P+ DI#1+ DI#1- PCOMMS P+ P- C+ DI#4+ DI#4- DIGITAL INPUTS C- SHLD +DI#1- +DI#2- +DI#3- +DI#4- SENSOR TH1 TH2 SHLD -12Vdc +12Vdc USE TERMINALS P+ AND P- FOR 12Vdc SIGNAL SOURCE OR USE AN EXTERNAL 24Vac SOURCE DI#1+ DI#1COMMS P+ P- C+ C- SHLD DI#4+ DI#4- DIGITAL INPUTS +DI#1- +DI#2- +DI#3- +DI#4- SENSOR TH1 TH2 SHLD 0Vac 24Vac 24Vac SOURCE Figure 3-16. MP REM, Digital Input Wiring.
Installation Instructions for Innotech Genesis Systems SECTION 4- COMMISSIONING 4-1. INTRODUCTION. The commissioning phase begins upon completion of the mechanical and electrical installation of the system and is the phase in which the user makes the system ready for operation.
Installation Instructions for Innotech Genesis Systems Make sure all units are located to provide safe access for operation and maintenance. Make sure all units are located where they are not subject to temperature extremes beyond the 0-40 C range. Make sure all units are located as far as practical from high current or high voltage cables or sources of RF emissions. 4-1.1.2. Electrical Inspection.
Installation Instructions for Innotech Genesis Systems Table 4-1. Genesis System Power Inputs.
Installation Instructions for Innotech Genesis Systems Check 24Vac and 24Vdc inputs as follows: a. Ensure power to the unit is turned off. b. For 24Vac units, ensure the AC Neutral is connected to Terminal 2 and the resistance between Terminal 2 and the enclosure’s main earth link is 3.0 Ohms, or less. c. Disconnect the power lead from Terminal 1 (Figure 4-1). d. Connect a digital voltmeter red (+) test lead to the disconnected power lead and the black (-) test lead to Terminal 2. e.
Installation Instructions for Innotech Genesis Systems 4-1.2.2. Checking Digital Input Wiring. Digital input wiring to controllers and digital input expansion modules should be checked to ensure the following conditions: The digital signal source voltage is within the correct range. Refer to Table 4-2 for digital input signal source specifications for the various digital input units. The signal polarity is correct for digital input signals with DC sources.
Installation Instructions for Innotech Genesis Systems DC SOURCE AC SOURCE JUMPER WIRE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 DIGITAL CONTROLLER 24V V AC V DC + 24V V AC V DC - CHECKING DC SOURCE + - CHECKING AC SOURCE Figure 4-2. Checking Digital Input Wiring. NOTE The following procedures assume the digital inputs are driven by Normally Open contacts. For digital inputs driven by Normally Closed contacts, the voltage indications should reverse. a.
Installation Instructions for Innotech Genesis Systems d. Ensure the voltmeter reads Zero Volts. If the reading is other than Zero Volts it indicates the input is driven by Normally Closed contacts or the input is not wired correctly. WARNING AVOID RISK OF ELECTRICAL SHOCK. OBSERVE ALL LOCAL ELECTRICAL SAFETY REQUIREMENTS WHEN PERFORMING THE NEXT STEP. e. With the voltmeter still connected, manually close the input contacts.
Installation Instructions for Innotech Genesis Systems g. Observe the voltmeter. It should indicate 0Vdc with the input switch closed. h. Release the manually-closed contacts. If a jumper wire was used in Step f., remove the jumper wire. i. Repeat Steps d. through h. for the remaining digital input channels. j. Remove operating power from the REM. k. Reconnect the RS485 cable that was disconnected in Step a.
Installation Instructions for Innotech Genesis Systems WARNING DIGITAL OUTPUTS ARE CONTROLLED BY RELAYS WITHIN THE ASSOCIATED GENESIS UNIT. THESE RELAYS ARE CONNECTED TO EXTERNAL CIRCUITS THAT CAN CONTAIN UP TO 240Vac. PROCEDURES IN THIS MANUAL REQUIRE CHECKING THESE CIRCUITS WITH POWER APPLIED. TO AVOID DEATH OR SERIOUS INJURY BY ELECTRICAL SHOCK, USE EXTREME CAUTION WHEN WORKING WITH ENERGISED CIRCUITS AND FOLLOW PRECAUTIONS IN THIS MANUAL.
Installation Instructions for Innotech Genesis Systems The output circuits are then checked for the opposite condition. For circuits using the NC contacts, the wire going the C terminal is temporarily disconnected and the associated device is checked to make sure it is de-energised. For circuits using the NO contacts, a jumper wire is temporarily connected between the NO and C terminals; the associated device is checked to make sure it is energised.
Installation Instructions for Innotech Genesis Systems CAUTION BEFORE PERFORMING THE FOLLOWING PROCEDURES, ENSURE THERE ARE NO SHORT CIRCUITS IN THE DIGITAL OUTPUT WIRING WHICH COULD CAUSE THE RELAY CONTACT CURRENT TO EXCEED 2 AMPERES. EXCESS RELAY CONTACT CURRENT WILL CAUSE PERMANENT AND IRREPARABLE DAMAGE TO THE UNIT. Following are the procedures for checking digital output wiring; refer to Section 3 for output terminal numbers for the applicable Genesis units: a.
Installation Instructions for Innotech Genesis Systems t. Remove operating power from the output device. u. Remove the jumper wire connected in Step q. v. Repeat Step m. through Step u. for the remaining output devices connected to the NO contacts. 4-1.2.4. Checking Analogue Input Wiring.
Installation Instructions for Innotech Genesis Systems Table 4-3. Analogue Input Checks. AISC MODEL INPUT TYPE PARAMETER MEASURED EXPECTED VALUE REFERENCE PARAGRAPH AIM AISC From AIM LEM Inspect Wiring N/A 4-1.2.4 DO5 Digital Voltage 0 or 5Vdc 4-1.2.4.1 D33 Digital Voltage 0 or 10Vdc 4-1.2.4.1 I05 0 – 5mA Passive Current (See Note) 0 – 5mA 4-1.2.4.2 I20 4 – 20mA Passive Current (See Note) 4 – 20mA 4-1.2.4.2 P20 Loop Powered Inspect Wiring N/A 4-1.2.4.
Installation Instructions for Innotech Genesis Systems 01 AI3 09 AI7 AI8 - - 12V PC G N Alternative Plug Style RS-485 G G 89 90 91 92 93 94 ANALOGUE INPUTS - 1 2 3 AI9 TD1: 0-250 µAmps A1 TD1: TD1: 0-250 µAmps µAmps + + + Sensor #2 Innotech Temperture Sensor #3 Innotech Temperture Sensor #4 Innotech Temperture Sensor #5 Innotech Temperture Sensor #6 Innotech Temperture Switchboard Temp Thermistor, Philips 10k AI LEM #1, Terminal 3 NC ANALOGUE INPUT SIGNAL SCREEN CONDITION
Installation Instructions for Innotech Genesis Systems Procedures for performing voltage checks are: CAUTION ENSURE THAT NO AC VOLTAGE IS PRESENT ON EITHER TERMINAL. AV VOLTAGEAT THE INPUT TERMINALS CAN CAUSE DAMAGE TO THE UNIT. ALSO, THE UNIT WILL NOT OPERATE PROPERLY IF THE ANALOGUE INPUT SIGNAL POLARITY IS INCORRECT. a. Ensure all AISCs have been removed and no power is applied to the Genesis unit. b. Connect a digital voltmeter to the input terminals; set the voltmeter to indicate Vac.
Installation Instructions for Innotech Genesis Systems CURRENT ACROSS 500 I05 0 – 5mA 0 – 2.5Vdc I20 4 – 20mA 2 – 10Vdc TD1 0 – 250 A 0 – 0.125Vdc TD2 0 – 500 A 0 – 0.25Vdc Inputs associated with the P20 AISC are 4 – 20mA loop-powered inputs. These inputs CANNOT be conveniently checked in the same manner as the other current inputs without applying power to the Genesis unit before it is safe to do so.
Installation Instructions for Innotech Genesis Systems 4-1.2.4.3. Resistance Checks. This paragraph contains procedures for checking analogue inputs associated with AISC Models TH1 through TH9. Checking these inputs consists of performing a simple continuity/resistance check. Procedures for performing voltage checks are: a. Ensure all AISCs have been removed and no power is applied to the Genesis unit. b. Set a digital ohmmeter to indicate Ohms.
Installation Instructions for Innotech Genesis Systems NOTE The analogue output circuit resistance for the Genesis I and II Digital Controllers and the GENII MPC should be at least 2,000 Ohms. The circuit resistance for the GENII AO REM should be at least 5,000 Ohms. g. Disconnect the meter and reconnect the signal wire disconnected in Step c. h. Repeat Step c. through Step g. for the remaining analogue outputs. i. Turn off any power applied in Step b. 4-1.3. INSTALL AISCs.
Installation Instructions for Innotech Genesis Systems Table 4-4. Units Requiring Jumper Settings. JUMPER TYPE: See Paragraph: ADDRESS END-OFCABLE ANALOGUE OUTPUT 4-1.4.1 4-1 .4.2 4-1.4.3 GENESIS II Digital Controller GENESIS I Digital Controller GENII MPC Mid Points Controller GENII AIM LEM GENII DIM LEM GENII DOM LEM GENII RMI GENII AI REM GENII AO REM GENII IDI REM GENII DI REM GENII DO REM GENII CS REM GENII MP REM GENII MZS REM 4-1.4.1. Address Jumpers.
Installation Instructions for Innotech Genesis Systems PORTION OF COMPUTER-GENERATED WIRING DIAGRAM SHOWING ANALOGUE INPUT MODULE - 1 2 3 A1 TD1: 0-250 µAmps Address jumpers A2 A1 A0 + TD1: TD1: 0-250 µAmps µAmps AI9 + TD1: 0-250 µAmps AI8 Sensor #11 + TD1: 0-250 µAmps AI7 Sensor #10 + TD1: 0-250 µAmps AI6 Sensor #9 + AI5 Sensor #8 A B C D E F G H I J Sensor #7 JUMPER OPEN Figure 4-6. Address Jumpers, Typical Settings.
Installation Instructions for Innotech Genesis Systems The computer-generated wiring diagram shows the location and jumper position for each analogue output in the system. Figure 4-8 shows a portion of a typical wiring diagram centred on a Genesis II Digital Controller’s analogue output jumpers. The figure shows how the jumpers are configured for the Variable and Heat Valve Modes of operation.
Installation Instructions for Innotech Genesis Systems 4-1.6. LOAD SOFTWARE AND CONFIGURE THE CONTROLLER(S). The Innotech configuration software program was prepared for your Genesis System at the factory before delivery of the system. The software contains all the data for internally configuring the controller(s) to perform the specific functions for which it was intended. Until the controller is configured, it can not accept input signals or produce outputs.
Installation Instructions for Innotech Genesis Systems c. Turn on the computer and allow it to boot-up. Turn on the controller’s operating power. NOTE The following procedures are limited to the steps necessary to configure the controller. For more detailed information on the operation of the zGen2Con software refer to the Innotech Genesis II Direct Digital Controller User Manual. d. Using standard Windows procedures, open the Gen2Cfg.320 folder. Note that the extension “.
Installation Instructions for Innotech Genesis Systems sensor or switch can be simulated to determine how the rest of the configuration reacts to the input. Detailed procedures for operation of the Gen2Mon Software is beyond the scope of this technical manual. Refer to the Innotech Genesis II Direct Digital Controller User Manual. 4-1.7.2. Performing Initial Tests. Because of the Genesis System’s designed-in flexibility, the various configurations can be vastly different from each other.
Installation Instructions for Innotech Genesis Systems CAUTION OPERATION OF THE GEN2MON SOFTWARE IN THE SIMULATION MODE PRESENTS A SERIOUS RISK TO THE SYSTEM. IN THE SIMULATION MODE, THE OPERATOR IS ACTUALLY FORCING VALUES INTO THE CONTROLLER. THEREFORE, IT IS POSSIBLE TO OVERCOME ANY OF THE NATURAL SAFEGUARDS WHICH MAY BE IN PLACE TO PROTECT THE PLANT. WHEN IN SIMULATION MODE, EXERCISE GREAT CARE IN ADJUSTING VALUES. THE SOFTWARE IS A POWERFUL FACILITY AND SHOULD NOT BE USED CARELESSLY. f.
Installation Instructions for Innotech Genesis Systems f. Disconnect the RS232 cable between the PC and the controller. g. Repeat procedures in Paragraphs 4-1.7.2.1 through 4-1.7.2.3 for the other controllers. 4-1.8. FINAL SYSTEM CHECKOUT. Final checkout of the system involves checking the operation of the system, performing any necessary adjustments and verifying that the system functions properly under normal operating conditions. Following are the procedures for performing final system checkout: a.
Installation Instructions for Innotech Genesis Systems APPENDIX A- NETWORK INSTALLATION A-1. OVERVIEW. The Innotech Genesis group of products uses serial communications (Comms) via standard RS485 physical networks to communicate data between themselves and to PCs connected to the network. The layout of the cables and the methods of connecting them are set out in this section. A-2. GENESIS I AND GENESIS II PRODUCTS.
Installation Instructions for Innotech Genesis Systems A-2.3. GENII RS485I ISOLATED RS485 COMMS. The GENII RS485I Isolated RS485 Comms Card is an optional daughter board that can be plugged onto the bottom board of a Genesis II Digital Controller to isolate the Digital Controller from the RS485 communications cable. A-3. GENESIS I AND GENESIS II CABLE SPECIFICATIONS. The cable should be designated as suitable for use in RS485 serial communications.
Installation Instructions for Innotech Genesis Systems A-4.1. GENESIS II COMMS WIRING TOPOLOGY. Bus topology is produced by connecting from one device to the next and then on to the next (Figure A-1). A simple means to identify if bus topology is used is to check that: • There are TWO end connections, and • Any joining is made between TWO cable ends only. Three or more cable ends at a joint indicates it is Star topology. The total continuous length of cable in one section is 1000 metres maximum.
Installation Instructions for Innotech Genesis Systems A-4.1.2. Linking Networks in Different Locations. When linking networks in different buildings, or when linking modules supplied from different switchboards, isolation must be provided to eliminate earth loops. Use a GENII RPTR Repeater Module to isolate the networks (Figure A-3). Note that the cable going to the more remote zone is always connected to Port 2 of the Repeater Module.
Installation Instructions for Innotech Genesis Systems A-4.2. GENESIS COMMS WIRING CONSIDERATIONS. The maximum number of nodes or devices that can be connected on one section of Comms cable is 32. This limit is set by the characteristics of the RS485 ICs. The maximum length of Comms cable is 1000 metres. This is determined by the characteristics of the RS485 ICs and by the characteristics of the cable. In practice, the maximum length of cable is determined by the quality of the signals.
Installation Instructions for Innotech Genesis Systems END CONNECTIONS 89 90 91 92 93 89 90 91 92 93 LOOPING CONNECTIONS 89 90 91 92 93 Screen Connected to Terminal 89 90 91 92 93 89 90 91 92 93 Screen Isolated From Terminal 89 90 91 92 93 94 89 90 91 92 93 94 Genesis II only Alternative Terminal Screen Connected 89 90 91 92 93 Screens Isolated and Joined Externally 89 90 91 92 93 Single Twisted Pair. Screens Isolated and Joined Externally Figure A-6. Genesis Comms Wiring Connections.
Installation Instructions for Innotech Genesis Systems A-4.2.2. Genesis I Connections. The Common connection provided by the tracks on the printed circuit board permanently links the following points: • • • • Terminal 2 (the Zero Volts of the AC supply) Terminals 19 and 20 (the connections for the screens of the analogue inputs) Terminal 91 (the connection for the screen of the Comms cable) The shell and Pin 5 of the DB9 connector for RS232.
Installation Instructions for Innotech Genesis Systems A-4.2.3. Genesis II Connections. The Common connection provided by the tracks on the printed circuit board permanently link the following points: • • • Terminal 2 (the Zero Volts of the AC supply), Terminals 19 and 20 (the connections for the screens of the analogue inputs), The shell and Pin 5 of the DB9 connector for RS232.
Installation Instructions for Innotech Genesis Systems A-4.2.4. GENII POLY SWITCH Board. The GENII POLY SWITCH RS485 Protection Plug board can only be used on Genesis II Digital Controllers. The POLY SWITCH board does not provide fully isolated data lines. It isolates the screen of the Comms cables from the Common on the Digital Controller. The POLY SWITCH board provides a level of protection against some types of overvoltage. It protects the RS485 ICs if 24Vac is applied to the Comms Terminals 89 to 93.
Installation Instructions for Innotech Genesis Systems A-4.2.5. GENII 485I Isolated RS485 Comms Card. The GENII 485I Isolated RS485 Comms card can only be used on Genesis II Digital Controllers. It provides galvanic isolation of the data lines of both the Net Comms and the Global Points and the screen connection at Terminal 91. To fit a GENII 485I card (See Figure A-10): a. Ensure that the power to all Digital Controller connections is turned off. b. Remove the top printed circuit board (six screws). c.
Installation Instructions for Innotech Genesis Systems A-4.2.6. GENII RPTR Repeater Module. The Repeater Module (Figure A-11) can be used with both the Genesis I and Genesis II Digital Controllers. The repeater’s function is to rebuild each data byte before re-transmitting it. There are two earth connections on the Repeater Module. The electrical earth must be connected at the E Terminal as it provides a creepage barrier for the mains voltage connection at the L and N Terminals.
Installation Instructions for Innotech Genesis Systems WARNING IF THE EARTH TERMINAL IS NOT CONNECTED TO THE ELECTRICAL EARTH, THE CABLE CONNECTED TO PORT 2 CAN REACH DANGEROUSLY HIGH VOLTAGES. Port 2 should be connected to the remote devices - the devices supplied from a different switchboard. If the Comms cable connection to Port 1 is an end connection and the Repeater Module is not the earth point for the screen, the screen of the Comms cable must not be connected to the terminal.
Socket on MPI viewed from rear of MPI NOTE On some units, wire colours may be different than as shown here. N- (blue) N+ (yellow) Gnd (green) Gnd (red) G- (black) Plug and Cable viewed as G+ (white) plugged into rear of MPI White Black Red Green Yellow Blue G+ GGnd Gnd N+ N- Installation Instructions for Innotech Genesis Systems COMMS CABLE CONNECTION ON MPI A non-isolated MPI has the three DB connector shells and the pins shown connected to COMMON.
Installation Instructions for Innotech Genesis Systems End Connection Screen is earthed to Terminal 91 only at this Digital Controller. 12 Screen SEE NOTE Looping Connection 12 Screen SEE NOTE Looping Connection 12 Screen SEE NOTE End Connection 12 Screen SEE NOTE NOTE Connection to Terminal 91 is fixed and cannot be opened. Figure A-13. Genesis I Non-Isolated Comms. A-4.2.9. Genesis II Non-Isolated Comms.
Installation Instructions for Innotech Genesis Systems The Genesis II has links that allow the screen connection of the RS485 Comms cable to be disconnected from the Common of the Digital Controller. Therefore, the screen(s) of the RS485 cable(s) can be joined in the Comms terminals of the Digital Controllers and still be isolated if only the four outer links are fitted. This is shown in Figure A-14 with the screen earthed at Digital Controller Number 2 because it has six links fitted.
Installation Instructions for Innotech Genesis Systems WARNING PARAGRAPHS A-4.2.9.1 AND A-4.2.9.2, BELOW, AND THEIR REFERENCED FIGURES DESCRIBE IMPROPER EARTHCONNECTION CONDITIONS THAT COULD LEAD TO SEVERE ELECTRICAL SHOCK OR DAMAGE TO EQUIPMENT. READ AND UNDERSTAND THESE PARAGRAPHS THOROUGHLY BEFORE MAKING ANY COMMS CONNECTIONS. A-4.2.9.1. Hazardous Earth-Connections. When the Digital Controllers are supplied and earthed from two different switchboards, a hazardous situation can be created.
Installation Instructions for Innotech Genesis Systems Figure A-16 shows a wiring arrangement that is slightly better. The earthing point for the screen is at the first Digital Controller in a group located together and supplied from one switchboard. It gives better protection to the greater number of Digital Controllers. This arrangement does not remove the hazard that the screen voltage at point A in the figure is not at the earth voltage of that Digital Controller.
Installation Instructions for Innotech Genesis Systems A-4.2.9.2. Use of GENII POLY SWITCH Boards. The GENII Poly Switch Boards provide some protection from over-voltage and voltage spikes. To achieve the maximum benefit, Poly Switches should be fitted to all Digital Controllers in a network. Fitting Poly Switches to all Digital Controllers results in the screen(s) being unearthed because the Poly Switches do not link the screen Terminal 91 to the Common and Terminal 2.
Installation Instructions for Innotech Genesis Systems Figure A-18 shows the preferred connection point for the screen earth. Fitting it on the screen terminal of one of a group of Digital Controllers gives optimum protection to the greater number of Digital Controllers. The earthing point for the screen is at the first Digital Controller in a group located together and supplied from one switchboard.
Installation Instructions for Innotech Genesis Systems A-4.2.10. Genesis II Isolated Comms. To remove the possibility of damaging the RS485 ICs, a GENII 485I Isolated RS485 Comms Card should be used. This card electrically isolates the screen and signal wires from all circuitry on the Digital Controller. It does not remove the electric shock hazard of the voltage difference between the screen, which is earthed, in Control Panel No. 2 and the earth in Control Panel No. 1.
Installation Instructions for Innotech Genesis Systems Figure A-20 shows the same arrangement as that shown in Figure A-19 but with the screen earthed in Control Panel No. 1 and GENII 485I cards fitted to all other Digital Controllers. This provides the same degree of isolation but is more expensive because three isolator cards are needed. All Digital Controllers remote from the point where the screen is earthed must be fitted with GENII 485I cards.
Installation Instructions for Innotech Genesis Systems A-4.2.11. Genesis II Comms. Isolated by Repeater. A GENII RPTR Repeater Module provides electrical isolation for all data conductors and for the screen of the Comms cable connected to Port 2 (Figure A-21). Therefore, Port 2 must be used to connect the Comms cable going to the remote devices. The screen of the cable connected to Port 2 should be earthed at a device in Control Panel No. 2.
Installation Instructions for Innotech Genesis Systems If the screen is connected to the SHLD terminal of Port 1 of the Repeater Module, then the connection of all other devices should ensure that the screen is isolated from the electrical earth. See Figure A-22. Switchboard or Control Panel No. 1 12 Switchboard or Control Panel No. 2 Repeater 2 Screen Isolated Earth Six outer links fitted. Screen is earthed via Terminal 2.
Installation Instructions for Innotech Genesis Systems A-4.2.12. GENII MPI with Non-Isolated Comms. When using a GENII MPI Modem and Printer Interface which has standard RS485 ICs, the RS485 connection is not isolated. Connecting a printer or a PC to the MPI will earth it. To prevent earth loops all other devices on that section of Comms cable must isolate the screen from the electrical earth.
Installation Instructions for Innotech Genesis Systems A better solution is to use an MPI that has RS485 isolation ICs and to fit a GENII 485I Isolated RS485 Comms card to the local Digital Controller and earth the screen at the first Digital Controller in Control Panel No. 2 as shown in Figure A-24. Switchboard or Control Panel No. 1 Screen 12 12 GEN4851 Card isolates Digital Isolated Controller from RS485 cable. Connect Screen M Printer C Screen Six outer links fitted.
Installation Instructions for Innotech Genesis Systems The following procedures should be performed in the order shown before application of power to the system: a. Ensure there are no network cables connected to any device. b. Connect the supply conductors to all devices, ensuring that, where it is specified, the electrical earth is connected to the device. c. Ensure that no conductors or screens of the network cables are in contact with any device or any metal. d.
Installation Instructions for Innotech Genesis Systems MPI With Isolated RS485 MPI With Non-Isolated RS485 PC PC MODEM MODEM PRINTER PRINTER Measure AC and DC voltages: Should be less than 3.5Vac and between +10Vdc and -5Vdc. 3.5 V AC V DC 24V V AC V DC Measure AC and DC voltages: Should be less than 24Vac and between +33Vdc and -33Vdc.
Installation Instructions for Innotech Genesis Systems A-28 Edition 011100
Installation Instructions for Innotech Genesis Systems APPENDIX B- DATA SHEETS B-1. INTRODUCTION. This appendix contains information in the form of the most recent data sheets for various items of Innotech hardware and software. These data sheets are mainly intended to provide installation information for miscellaneous ancillary units not covered elsewhere in this manual. The specific data sheets in this appendix have been selected for inclusion based on the configuration of your Genesis System.
Installation Instructions for Innotech Genesis Systems Controllers - Continued DS 2.41 DS 2.51 DS 2.61 IDC4001 IPC40hc IMC40hc DS 2.62 IMC42hc DS 2.63 IMC43hc DS 2.64 IMC50hc DS 2.65 IMC52hc DS 2.66 IMC53hc DS 2.70 MS01-01 DS 2.71 MS1-03 DS 2.72 MS1-05 DS 2.83 DS 2.84 DS 2.85 DS 2.91 DS 2.92 DS 2.93 DS 2.94 DS 2.95 DS 2.96 DS 2.
Installation Instructions for Innotech Genesis Systems Displays DS 4.11 DS 4.21 DS 4.22 IDD4001 IDW400n IDW4x12 DS 4.31 DS 4.32 DS 4.41 DS 4.51 DS 4.61 DS 4.62 IDS40nn IDS4212 IDD5001 IDW IDS50 IDS5212 Digital Display Wall Displays Wall Displays with Remote Set Point Adjust Switchboard Displays Multipoint Temperature Display Digital Display Wall Display Switchboard. Digital Display Multipoint Temperature Display Signal Adaptors DS 5.11 DS 5.21 DS 5.31 DS 5.32 IMF4x0n IAS40nn IHS40nn IHS4207 DS 5.
Installation Instructions for Innotech Genesis Systems Genesis Hardware - Continued DS AO REM DS DI REM DS DO REM DS IDI REM DS CS REM DS MZS REM DS MP REM DS MPC GENII AO REM Analogue Output Module GENII DI REM Dry Contact Digital Input Module GENII DO REM Relay Output Module GENII IDI REM Opto Isolated Digital Input Module GENII CS REM Control Station Module GENII MZS REM Multi Zone Station Remote Expansion Module GENII MP REM Multipoint Module GENII MPC Mid Points Controller Genesis II Software DS CON
R P.O. Box 292 Sunnybank Brisbane Australia. 4109 Phone: 61 7 38411388 Fax: 61 7 38411644 Website: http://www.innotech.com.au E-mail: sales@ innitech.com.
