Genesis II Direct Digital Controller INSTALLATION INSTRUCTIONS
Proprietary No part of this technical manual 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 Mass Electronics Pty Ltd. Trademark The term ‘Innotech’ used in this manual is a trademark of Mass Electronics Pty Ltd trading as Innotech Control Systems Australia.
Document Management Document Title: Genesis II Installation Instructions Revision History Version Number Date Summary of Changes 1.0 June 2010 Document first edition 2.0 December 2013 Contact Details update, style update Edition 2.
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Contents Chapter 1 - Preliminary Information..............................................................11 1-1 Introduction.............................................................................................................. 12 1-1.1 Systems Covered by this Manual.............................................................................12 1-1.2 Scope of this Technical Manual...............................................................................13 1-2 Special Considerations............
Contents (Continued) 3-4 Wiring of Remote Expansion Modules..................................................................... 50 3-4.1 REM Power Connections..........................................................................................50 3-4.2 REM Comms Connections........................................................................................51 3-4.3 GENII AI REM Analogue Input Module......................................................................52 3-4.
Contents (Continued) Chapter 5 - Network Installation................................................................. 101 5-1 Overview................................................................................................................. 102 5-2 Genesis II Products................................................................................................. 102 5-2.1 Definitions...............................................................................................................
List of Illustrations Figure 2-1: Genesis II Direct Digital Controller Dimensions......................................................17 Figure 2-2: Genesis II DDC Plastic Lid Clamping Details...........................................................18 Figure 2-3: MPCII Mid Point Controller Dimensions..................................................................19 Figure 2-4: GenII AI REM Analogue Input Module......................................................................
List of Illustrations (Continued) Figure 3-23: SENRx Wireless Temperature Sensor (Back View)..................................................73 Figure 4-1: Checking Power Input..............................................................................................79 Figure 4-2: Checking Digital Input Wiring..................................................................................81 Figure 4-3: Checking Dry Contact Inputs........................................................................
List of Tables Table 1-1: Document Chapters.................................................................................................13 Table 3-1: Nominal Resistance for Wire Sizes at 20°C..............................................................33 Table 3-2: Genesis II DDC Power Input Signal Conditions.......................................................36 Table 3-3: Genesis II DDC Input Signal Conditions..................................................................
Genesis II Direct Digital Controller INSTALLATION INSTRUCTIONS Chapter 1 - Preliminary Information
Genesis II Installation Instructions 1-1 Introduction This manual is intended to provide qualified technical personnel with complete and easy-to-follow instructions for the installation, checkout and commissioning of the Innotech Genesis II Direct Digital Controller and MPCII Mid Points Controller.
Genesis II Installation Instructions Some of the ancillary units included in the Genesis II System are (refer to the System Description Manual for descriptions of these units): • Several types of Remote Expansion Module (REM) • Miscellaneous Ancillary Units 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 II System.
Genesis II Installation Instructions 1-2 Special Considerations The following precautions and installation considerations must be observed to ensure personal safety and to prevent damage to equipment: • Local safety regulations, building codes and ordinances must be complied with during installation. In cases of conflict with procedures in this manual, contact Innotech or its authorised representative for clarification.
Genesis II Direct Digital Controller INSTALLATION INSTRUCTIONS Chapter 2 - Mechanical Installation
Genesis II Installation Instructions 2-1 Introduction This section of the manual contains instructions and related data to facilitate the installation of components of the Genesis II System. It is recommended that the main units of the Genesis II System, such as the Genesis II Direct Digital Controller (DDC), MPCII Mid Points Controller and standard Innotech Remote Expansion Modules (REM) be mounted in steel cabinets to minimise the effects of electromagnetic interference (EMI).
Genesis II Installation Instructions 2-2.1.1 Genesis II Direct Digital Controller The Innotech Genesis II Direct Digital Controller is a state-of-the-art processing system that has the capability of controlling various types of industrial systems. The Genesis II Direct Digital Controller is housed in a rectangular case suitable for Switchboard Mounting. The housing is made from flame retardant plastics recognised by UL as UL 94-V0. Refer to Figure 2-1.
Genesis II Installation Instructions The unit’s circuit boards are mounted inside the case, which consists of a base and a lid. The plastic base has eight mounting holes; each hole is 4mm in diameter. Not all of the eight holes are required for mounting, provided 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 case’s plastic lid to the motherboard.
Genesis II Installation Instructions 2-2.1.2 MPC II Mid Points Controller The Innotech MPCII Mid Points Controller is a state-of-the-art processing system that has the capability of controlling various types of industrial systems. The MPCII Mid Points Controller can be used in a Genesis II System as the main controller. It is housed in a case suitable for Switchboard Mounting. The housing is moulded from flame retardant plastics recognised by UL as UL 94-V0.
Genesis II Installation Instructions 2-2.2.1 REM I/O Expansion Modules REM I/O Expansion Modules increase the Input and/or Output capabilities of a Genesis II Series digital controller. There are a total of six different REM I/O Expansion Modules.
Genesis II Installation Instructions 2-2.2.2 REM Control Station Modules REM Control Station Modules are housed in a switchplate that mounts in standard electrical wall plates at a remote location. Mechanical installation instructions for the REM Control Station Modules are not applicable; electrical installation instructions for these modules are contained in the Electrical Installation Chapter. There are a total of three different REM Control Station Modules.
Genesis II Installation Instructions 2-2.2.3 REM Multi Zone Station Modules REM Multi Zone Station Modules are housed in a switchplate that mounts in standard electrical wall plates at a remote location. Mechanical installation instructions for the REM Multi Zone Station Modules are not applicable; electrical installation instructions for these modules are contained in the Electrical Installation chapter. There are a total of two different REM Multi Zone Station Modules.
Genesis II Installation Instructions 2-2.2.4 REM Multipoint Modules REM Multipoint Modules provide additional Analogue/Digital output capabilities for a Genesis II Series digital controller. There are a total of three different REM Multipoint Modules. • GENII MP405 REM Multipoint Module • GENII MP423 REM Multipoint Module • GENII MP432 REM Multipoint Module Common Enclosure Information The above listed REM Multipoint Modules are housed in a rectangular case suitable for DIN Rail mounting.
Genesis II Installation Instructions 2-2.2.5 REM Wireless Sensor Modules Wireless Temperature Sensor REMs increase the capability of a Genesis II System by allowing wireless temperature sensor’s to interface with the digital controller. The use of Wireless Temperature Sensor REMs is facilitated through the Wireless Module Interface, with connects directly to the REM socked on the digital controller.
Genesis II Installation Instructions GENII SENRx Wireless Temperature Sensors The GENII SENRx Wireless Temperature Sensors are housed in a square case manufactured from an ignition resistant grade of ABS, which meets the requirements of AS2420.
Genesis II Installation Instructions 2-3 Installation Instructions A steel enclosure is recommended to contain the system with the aim of minimizing EMI from surrounding equipment. To allow for the number of cables to enter and leave the enclosure, the minimum dimensions of slotted cable ducts should be 45mm x 45mm with 65mm clearance from the cable ducts to the terminals of the units.
Genesis II Installation Instructions Figure 2-11 shows an example of a typical Genesis II System layout in an equipment enclosure.
Genesis II Installation Instructions 2-3.2 General Installation Instructions To ensure continued reliable operation of the Genesis II System, the following installation guidelines should be observed: • The Genesis II Direct Digital Controller or MPCII Mid Points Controller should be installed in a position that provides easy access to the front panel and sufficient room for power, and input/ output cabling.
Genesis II Installation Instructions 2-4 Difference Data This paragraph contains difference data unique to installation of the MPCII Mid Points Controller, Genesis II System REMs and related devices. Installation instructions provided in Section 2-3 are applicable except where stated otherwise. 2-4.1 REM Limitations The following limitations apply to the installation of REMs: • A Genesis II Direct Digital Controller must have Version 4 firmware or greater installed to support REM Modules.
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Genesis II Direct Digital Controller INSTALLATION INSTRUCTIONS Chapter 3 - Electrical Installation
Genesis II Installation Instructions 3-1 Introduction This section of the manual contains instructions and related data to facilitate the electrical installation of the Genesis II System. Because of the designed-in flexibility of the Genesis II System, it can be installed in a wide variety of configurations, depending on the user’s preference. For this reason, it is not possible to include all the various installation configurations in this manual.
Genesis II Installation Instructions Cabling plays an important role in the installation of Genesis II Systems. The following general cabling guidelines should be observed: • In all cases, use electromagnetic-shielded cable for sensor wiring. • When necessary to protect cabling from physical damage, both shielding and physical protection may be provided by running the cable in a metal conduit. Alternatively, use steel wire armoured (SWA) cable, which also contains an electromagnetic shield.
Genesis II Installation Instructions Below is an example of a typical computer-generated wiring diagram. A printout of the wiring diagram and materials list is usually provided at the time of hardware delivery. Refer to Figure 3-1. Figure 3-1: Computer Generated Wiring Diagram Example Edition 2.
Genesis II Installation Instructions 3-3.1 Genesis II Direct Digital Controller Figure 3-2 shows the input/output connection groups for the Genesis II Direct 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 (3-3.1.1) • Digital Inputs (3-3.1.2) • Digital Outputs (3-3.1.3) • Analogue Inputs (3-3.1.
Genesis II Installation Instructions 3-3.1.1 Power Input The Genesis II Direct Digital Controller's power requirements are one of the following: • 24VAC ±10%, 50/60 Hz, Power Consumption: 15 VA. • 24VDC ±10%, Power Consumption: 8 Watts. The operating voltage must meet the requirements of Safety Extra Low Voltage (SELV) to EN60730. The transformer used must be a safety transformer in compliance with EN60742 and be designed for 100% duty.
Genesis II Installation Instructions 3-3.1.2 Digital Inputs The Genesis II Direct Digital Controller’s eight Digital Input channels (Terminals 4 to 19) provide the capability of directly interfacing to digital input signal sources such as pushbutton switches and relay contacts. Because each Digital Input channel is isolated, the power source for the signal must be external to the controller. This signal source can be AC or DC. If the source is AC, it can be provided by the auxiliary transformer.
Genesis II Installation Instructions 3-3.1.3 Digital Outputs Each of the Genesis II Direct Digital Controller’s twelve digital output channels (Terminals 42–65) consists of a single-pole, double-throw (SPDT) relay. The two terminals assigned to each channel represent the associated relay’s Normally Open (NO) and Common (COM) contacts. Digital output relay contacts are rated at 24VAC, 2A.
Genesis II Installation Instructions 3-3.1.4 Analogue Inputs The Genesis II Direct Digital Controller’s eight Analogue Input channels (Terminals 22-37) allow the direct interface of various analogue inputs, such as Thermistor, 0-10VDC, 0-5VDC and 4-20 mA 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 (see Commissioning).
Genesis II Installation Instructions 3-3.1.5 Analogue Outputs Sixteen Analogue Output channels are provided. Each channel can be configured, through the Gen2Config 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. In the Heat Valve Mode, the output signal consists of Pulse-Width Modulated (PWM), 0-10V, high-speed pulses at 5mA.
Genesis II Installation Instructions Refer to Table 3-6 below for Analogue Output terminal numbers. There are 16 Analogue active signal terminals (AO1 through AO16), one for each channel and eight return (Common) terminals. The fewer number of Common terminals is intended to reduce the overall number of terminals. Cable screening may be terminated into the Screens Terminals (20 and 21), space permitting.
Genesis II Installation Instructions 3-3.1.6 Pulse Counter Inputs A single, high-speed Digital Input is provided to facilitate the counting of rectangular wave signals (0-10VDC up to 0-24VDC, for pulse frequencies up to 1 kHz). Refer to Table 3-7 for terminal number assignments. Terminals 38 and 39 provide 24VDC power to the pulse source, if required. Terminals 40 and 41 are the pulse-input terminals. The input is polarity sensitive so it is important that correct polarity be observed.
Genesis II Installation Instructions 3-3.2 MPCII Mid Points Controller Figure 3-4 shows the input/output connection groups for the MPCII Mid Points Controller. The MPCII Mid Points Controller uses terminal strips located around the controller’s perimeter. Terminals are grouped by function as follows: • Power Input (3-3.2.1) • Digital Inputs (3-3.2.2) • Digital Outputs (3-3.2.3) • Analogue Inputs (3-3.2.4) • Analogue Outputs (3-3.2.
Genesis II Installation Instructions 3-3.2.1 Power Input The MPCII Mid Points Controller's power requirements are one of the following: • 24VAC ±10%, 50/60Hz, Power Consumption: 7 VA • 24VDC ±10%, Power Consumption: 4 Watts The operating voltage must meet the requirements of Safety Extra Low Voltage (SELV) to EN60730. The transformer used must be a safety transformer in compliance with EN60742 and be designed for 100% duty. It must also be sized and fused in compliance with local safety regulations.
Genesis II Installation Instructions 3-3.2.2 Digital Inputs The MPCII Mid Points Controller’s four Digital Input channels (Terminals 4 to 11) provide the capability of directly interfacing to digital input signal sources such as pushbutton switches and relay contacts. Because each Digital Input channel is isolated, the power source for the signal must be external to the controller. This signal source can be AC or DC. If the source is AC, it can be provided by the auxiliary transformer.
Genesis II Installation Instructions 3-3.2.3 Digital Outputs Each of the MPCII Mid Points Controller’s eight digital output channels consists of a single-pole, double-throw (SPDT) relay. The two terminals assigned to each channel represent the associated relay’s Normally Open (NO) and Common (COM) contacts. Digital output relay contacts are rated at 24VAC, 2A (to be supplied by a Class 2 Transformer).
Genesis II Installation Instructions 3-3.2.4 Analogue Inputs The MPCII Mid Points Controller’s four Analogue Input channels 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 (Mechanical Installation).
Genesis II Installation Instructions 3-3.2.5 Analogue Outputs The MPCII Mid Points Controller has four Analogue Output channels. Each channel can be configured, through the Gen2Config 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. In the Heat Valve Mode, the output signal consists of Pulse-Width Modulated (PWM), 0-10V, high-speed pulses at 5mA.
Genesis II Installation Instructions Refer to Table 3-12 for Analogue Output terminal number assignments: NOTE Screen Terminals, located between the Analogue Output terminals AO 2 and AO 3 on the MPCII Mid Points Controller, are provided for terminating Analogue Output Cable Screens.
Genesis II Installation Instructions 3-4 Wiring of Remote Expansion Modules The following paragraphs contain wiring information for the following types of Remote Expansion Modules (REMs) used in the Genesis II System: • GENII AI REM Analogue Input Module (3-4.3) • GENII AO REM Analogue Output Module (3-4.4) • GENII DI REM Dry Contact Digital Input Module (3-4.5) • GENII DO REM Digital Output Module (3-4.6) • GENII IDI REM Opto Isolated Digital Input Module (3-4.
Genesis II Installation Instructions 3-4.2 REM Comms Connections The RS485 Comms link between the Genesis II Direct Digital Controller and REMs, or the MPCII Mid Points Controller and REMs, is designed to allow reliable communications over long distances in electrically adverse signal conditions.
Genesis II Installation Instructions 3-4.3 GENII AI REM Analogue Input Module The GENII AI REM Analogue Input Module (Figure 3-7) is powered by 24VAC ±10% @ 50/60 Hz. Power Consumption is 4 VA maximum. The GENII AI REM provides for six analogue inputs from field equipment. Each Analogue Input circuit has a socket for fitting an Analogue Input Signal Conditioner (AISC), which defines the input type and range selection.
Genesis II Installation Instructions 3-4.4 GENII AO REM Analogue Output Module The GENII AO REM Analogue Output Module (Figure 3-8) is powered by 24VAC ±10% @ 50/60 Hz. Power Consumption is 4VA maximum. The GENII AO REM provides up to five Analogue Outputs to be connected to field equipment. Jumpers on the board allow for either Linear 0-10V (maximum load 2mA) or PWM 10Vpp (maximum load 2mA) output settings for each channel.
Genesis II Installation Instructions The RS485 Comms connection block is in the upper right section of the module and the End of Cable Jumper is next to it. Analogue Output terminals are located at the bottom of the module; output signal connections are listed below in Table 3-14. Analogue Output cables should be run using twisted pair shielded cable. The screens should be connected to the signal’s negative output terminal (B, D, F, H or J) in each case.
Genesis II Installation Instructions The RS485 Comms connection block is in the upper right section of the module and the End of Cable Jumper is next to it. Digital Input terminals are located at the bottom of the module; input signal connections are listed in Table 3-15.
Genesis II Installation Instructions 3-4.6 GENII DO REM Relay Output Module The GENII DO REM Relay Output Module (Figure 3-10) is powered by 24VAC ±10% @ 50/60 Hz. Power Consumption is 4VA maximum. The GENII DO REM provides 5 Relay Outputs (2A @ 24VAC – Normally open contacts) to control or switch field equipment.
Genesis II Installation Instructions 3-4.7 GENII IDI REM Opto Isolated Digital Input Module The GENII IDI REM Opto Isolated Digital Input Module (Figure 3-11) is powered by 24VAC ±10% @ 50/60Hz. Power Consumption is 4VA maximum. The GENII IDI REM provides 5 opto isolated digital inputs to sense signals from field equipment. The voltage detection range is 12 to 24 volts AC or DC.
Genesis II Installation Instructions 3-4.8 GENII PI REM Pulse Input Module The GENII PI REM Pulse Input Module (Figure 3-12) is powered by 24VAC ±10% @ 50/60 Hz. Power Consumption is 4 VA maximum. The GENII PI REM provides 5 opto isolated digital inputs to sense pulsed signals from field equipment. The voltage detection range is 12 to 24VDC. The GENII PI REM detects pulses with a minimum on time of 20ms, with a minimum off time of 20ms, which gives a maximum of 25 pulses per second.
Genesis II Installation Instructions 3-4.9 GENII MZS REM Multi Zone Station Module The GENII MZS REM Multi Zone Station Module (Figure 3-13) is powered by 24VAC ±10% @ 50/60Hz. Power Consumption is 3VA maximum. The GENII MZS REM mounts into a standard electrical wall plate. The only connections to the GENII MSZ REM are 24VDC power and the RS485 Comms link. Locations of electrical terminals are shown in Figure 3-13, which is a rear view of the module.
Genesis II Installation Instructions 3-4.10 GENII MZSAH REM Multi Zone Station A/H Module The GENII MZSAH REM Multi Zone Station A/H Module is powered by 24VAC ±10% @ 50/60Hz. Power Consumption is 3VA maximum. The GENII MZSAH REM mounts into a standard electrical wall plate. The only connections to the GENII MZSAH REM are 24VAC power and the RS485 Comms link. Locations of electrical terminals are shown in Figure 3-14, which is a rear view of the module.
Genesis II Installation Instructions 3-4.11 GENII CS REM Control Station Module The GENII CS REM Control Station Module is powered by 24VAC ±10% @ 50/60Hz. Power Consumption is 3 VA maximum. The GENII CS REM mounts into a standard electrical wall plate. The only connections to the GENII CS REM are 24VAC power and the RS485 Comms link. Locations of electrical terminals are shown in Figure 3-15, which is a rear view of the module.
Genesis II Installation Instructions 3-4.12 GENII CSAH REM Control Station A/H Module The GENII CSAH REM is powered by 24VAC ±10% @ 50/60 Hz. Power Consumption is 3VA maximum. The GENII CSAH REM mounts into a standard electrical wall plate. The only connections to the GENII CSAH REM are 24VAC power and the RS485 Comms link. Locations of electrical terminals are shown in Figure 3-16, which is a rear view of the module.
Genesis II Installation Instructions 3-4.13 GENII CSFCAH REM Control Station Fan Control A/H Module The GENII CSFCAH REM Control Station Fan Control, A/H Module is powered by 24VAC ±10% @ 50/60 Hz. Power Consumption is 3VA maximum. The GENII CSFCAH REM mounts into a standard electrical wall plate. The only connections to the GENII CSFCAH REM are 24VAC power and the RS485 Comms link. Locations of electrical terminals are shown in Figure 3-17, which is a rear view of the module.
Genesis II Installation Instructions 3-4.14 GENII MP405 REM Multipoint Module The Innotech GENII MP405 REM Multipoint Module is a remote expansion device that has both input and output expansion capabilities. The GENII MP405 REM provides relay outputs for distributed control, digital inputs for status detection and Thermistor inputs for temperature measurement. The GENII MP405 REM (Figure 3-18) is powered by 24VAC ±10% @ 50/60 Hz, or powered by 24VDC ±15%. Power Consumption is 4VA maximum.
Genesis II Installation Instructions I/O Terminal Connections for the GENII MP405 REM Multipoint Module are listed in Table 3-19 and Table 3-20.
Genesis II Installation Instructions 3-4.15 GENII MP414 REM Multipoint Module The Innotech GENII MP414 REM Multipoint Module is a remote expansion device that has both input and output expansion capabilities. The GENII MP414 REM provides relay outputs for distributed control, digital inputs for status detection and Thermistor inputs for temperature measurement. The GENII MP414 REM (Figure 3-19) is powered by 24VAC ±10% @ 50/60Hz, or powered by 24VDC ±15%. Power Consumption is 4 VA maximum.
Genesis II Installation Instructions I/O Terminal Connections for the GENII MP414 REM Multipoint Module are listed in Table 3-21 and Table 3-22.
Genesis II Installation Instructions 3-4.16 GENII MP423 REM Multipoint Module The Innotech GENII MP423 REM Multipoint Module is a remote expansion device that has both input and output expansion capabilities. The GENII MP423 REM provides relay outputs for distributed control, digital inputs for status detection and Thermistor inputs for temperature measurement. The GENII MP423 REM (Figure 3-20) is powered by 24VAC ±10% @ 50/60 Hz, or powered by 24VDC ±15%. Power Consumption is 4 VA maximum.
Genesis II Installation Instructions I/O Terminal Connections for the GENII M423 REM Multipoint Module are listed in Table 3-23 and Table 3-24.
Genesis II Installation Instructions 3-4.17 GENII MP432 REM Multipoint Module The Innotech GENII MP432 REM Multipoint Module is a remote expansion device that has both input and output expansion capabilities. The GENII MP432 REM provides relay outputs for distributed control, digital inputs for status detection and Thermistor inputs for temperature measurement. The GENII MP432 REM (Figure 3-21) is powered by 24VAC ±10% @ 50/60Hz, or powered by 24VDC ±15%. Power Consumption is 4 VA maximum.
Genesis II Installation Instructions I/O Terminal Connections for the GENII M432 REM Multipoint Module are listed in Table 3-25 and Table 3-26.
Genesis II Installation Instructions 3-4.18 GENII WMI Wireless Module Interface The Innotech GENII WMI Wireless Module Interface is a remote expansion for the Genesis II Direct Digital Controller or MPCII Mid Points Controller. The GENII WMI provides an interface to the SENRx series of wireless temperature sensors. The GENII WMI (Figure 3-22) is powered by 24VAC ±10% @ 50/60Hz. Power Consumption is 4 VA maximum. There are no inputs or outputs on a GENII WMI.
Genesis II Installation Instructions 3-4.19 SENRx Series Wireless Temperature Sensors The Innotech SENRx Series Wireless Temperature Sensors are remote expansion devices for the Genesis II range of digital controllers. There are four unique models in the SENRx series: • SENR1: Temperature Sensor, Low Battery Indicator. • SENR2: Temperature Sensor, Low Battery Indicator, Set Point Adjustment. • SENR5: Temperature Sensor, Low Battery Indicator, After Hours Button.
Genesis II Installation Instructions SENRx modules should be mounted within a 20 m radius (depending on obstructions) of the GENII WMI Wireless Module Interface in a dry and clean location free of excess vibration. To remove the battery from a SENRx module, simply insert a flat screwdriver underneath the battery between the two clips and lever the battery out (Figure 3-23). When re-inserting the battery, press and hold the “RESET” button.
Genesis II Direct Digital Controller INSTALLATION INSTRUCTIONS Chapter 4 Commissioning
Genesis II Installation Instructions 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.
Genesis II Installation Instructions 4-1.1.2 Electrical Inspection • Make sure all sources of electrical power, including power to ancillary items are off. • Check all input and output connections against the computer-generated wiring diagram supplied for your installation. • Ensure all connections are in accordance with the wiring diagram and that connections are solidly made. • Ensure all enclosures are solidly earthed.
Genesis II Installation Instructions Table 4-1: Genesis II System Power Inputs Operating Voltage Unit 24VAC ±10% 24VDC ±10% GENII DDC Digital Controller Yes Yes MPCII Mid Points Controller Yes Yes GENII AI REM Analogue Input Module Yes No GENII AO REM Analogue Output Module Yes No GENII DI REM Dry Contact Digital Input Module Yes No GENII DO REM Relay Output Module Yes No GENII IDI REM Opto-Isolated Digital Input Module Yes No GENII PI REM Pulse Input Module Yes No GENII MZS RE
Genesis II Installation Instructions Check 24VAC and 24VDC inputs as follows: 1. Ensure power to the unit is turned off. 2. 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. 3. Disconnect the power lead from Terminal 1 (Figure 4-1). 4. Connect a digital volt-ohm-meter red (+) test lead to the disconnected power lead and the black (-) test lead to Terminal 2. 5.
Genesis II Installation Instructions 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.
Genesis II Installation Instructions CAUTION Avoid risk of electrical shock observe all local electrical safety requirements when performing the nest step. 5. With the voltmeter still connected, manually close the input contacts. If it is not possible to close the circuit manually, connect a jumper wire across the contacts at the switching device, as shown in Figure 4-2. 6. Ensure the voltmeter indicates the proper signal voltage as listed in Table 4-2. 7.
Genesis II Installation Instructions 4-1.2.4 Internal-Source Digital Inputs The GENII DI REM provides eight dry contact (voltage-free) inputs to sense contact closure from field equipment. The eight digital inputs are connected to terminals A through H (see Figure 4-3). Contacts I and J are signal common terminals. The REM provides 5VDC between each input and common. This voltage is shorted to common when the switch is closed. Check the digital input wiring as follows: 1.
Genesis II Installation Instructions GENII DI REM A B C D E F G H I J 5V V AC V DC SWITCH OPEN - + GENII DI REM A B C D E F G H I J 0V V AC V DC SWITCH CLOSED + - Figure 4-3: Checking Dry Contact Inputs 4-1.2.5 Checking Digital Output Wiring Digital outputs of the various units are interfaced through relays, each having single-pole changeover contacts.
Genesis II Installation Instructions Before checking the digital output circuits, it is important to ensure that there are no short circuits in the external wiring which could cause the contact current to exceed the rated amount. Current in excess of this through the relay contacts will result in permanent damage to the unit. Following is a general description of the process for safely checking digital output circuits.
Genesis II Installation Instructions RELAY ON RELAY OFF 42 43 44 45 46 47 48 4 NO C NO C NO C NO 240V V AC V DC + 0V V AC V DC EXTERNAL DEVICE - 0V GENESIS II DIGITAL CONTROLLER TERMINALS + - 24V 0V 24V AC/DC AC/DC Figure 4-4: Checking Digital Output Wiring 4-1.2.
Genesis II Installation Instructions NOTE Current value is determined by measuring voltage across a resistor in series. Table 4-3: Analogue Input Checks AISC Model Input Type Parameter Measured Expected Value Reference Paragraph DO5 Digital Voltage 0 or 5VDC 4-1.2.7 D33 Digital Voltage 0 or 10VDC 4-1.2.7 IO5 0 - 5mA Passive Current (see Note) 0 - 5mA 4-1.2.8 I20 4 - 20mA Passive Current (see Note) 4 - 20mA 4-1.2.8 P20 Loop Powered Inspect Wiring 4-1.2.
Genesis II Installation Instructions For example, an analogue input channel that has Model TH2 AISC assigned receives its input from a thermistor device; the input circuit is checked by measuring its resistance, which should be between 0 and 2k. Procedures for checking the resistance are contained in section 4-1.2.9. The type of AISC for each analogue input channel is determined when the system configuration is established by the Genesis Configuration Software prior to delivery.
Genesis II Installation Instructions 4-1.2.7 Voltage Checks IMPORTANT The wiring checks in the following paragraphs are performed with AISCs removed. The units are delivered with their AISCs removed. Do not install the AISCs until all wiring checks are completed. This paragraph contains procedures for checking analogue inputs associated with AISC Models D05, D33, V05 and V10.
Genesis II Installation Instructions The matrix below lists the expected voltages to be measured across a 500 Ohm resistance for the various values of input current. For other resistor values use Ohm’s Law (V=IR) to determine the voltage. INPUT VOLTAGE AISC CURRENT ACROSS 500 ohms I05 0 – 5 mA 0 – 2.5VDC I20 4 – 20 mA 2 – 10VDC TD1 0 – 250 A 0 – 0.125VDC TD2 0 – 500 A 0 – 0.25VDC Inputs associated with the P20 AISC are 4 – 20 mA loop-powered inputs.
Genesis II Installation Instructions 4-1.2.10 Checking Analogue Output Wiring Analogue output wiring is checked for the following reasons: • To ensure the analogue output terminals are free of any external voltage • To check continuity through the external analogue circuit • To ensure the resistance of the external analogue circuit is sufficient to avoid overloading the analogue output circuit.
Genesis II Installation Instructions 4-1.4 Set Jumper Plugs Various jumper plugs throughout the system must be set properly before power can be applied to the system. There are 4 categories of jumper plug: Address Plugs set the address of each Remote Expansion Module • Analogue Output plugs are used to select either Variable or Heat Valve Mode of operation for analogue outputs. Refer to section 3-3.1.5 for a definition of Variable and Heat Valve Modes.
Genesis II Installation Instructions 4-1.4.1 Address Jumpers Locations and settings of address jumpers are shown on the computer-generated wiring diagram provided with the system hardware. Figure 4-6 shows a portion of a typical computer-generated wiring diagram. Address jumper connectors are A0, A1, A2 and A3. Open jumper connectors are shown in grey on the wiring diagram. Connectors shown in black require a jumper to be installed.
Genesis II Installation Instructions 4-1.4.2 End of Cable Jumpers Although the locations of End-of-Cable jumpers are not shown on the computer-generated wiring diagram, they are easily located close to the unit’s RS485 Comms connector. Figure 4-7 shows the location of the End-of-Cable jumper for a GENII AI REM unit. Jumpers for other units are similarly placed.
Genesis II Installation Instructions 4-1.4.3 Analogue Output Jumpers An analogue output jumper plug arrangement is provided for each analogue output channel. The three-pin jumper sockets will accept a shorting plug between the centre pin and either of the outside pins. Depending upon which pair of pins the jumper is connected to, the analogue output is configured for either the Variable Mode or the Heat Valve Mode. For inactive analogue output channels, the jumper is not installed in either position.
Genesis II Installation Instructions 4-1.4.4 Frequency Jumpers The GENII WMI Wireless Module Interface provides an interface to the SENRx series of wireless temperature sensors. There are four user selectable frequency jumpers for configuration. To enable correct communication over a wireless frequency, the settings of these jumpers must be matched. Locations and settings of frequency jumpers a fare shown on the datasheets for each of these products.
Genesis II Installation Instructions 4-1.5 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.
Genesis II Installation Instructions 4-1.5.2 Configuring a Controller The following is the procedure for configuring a controller: 1. Turn off the electrical power to the controller. 2. Connect to the controller via an RS232 cable, RJ45 or over a connected Innotech network. 3. Turn on the computer and allow it to boot-up. Turn on the controller’s operating power. 4. Using standard Windows procedures, open the Gen2Config folder. 5. Click on the Gen2Config icon to open the Gen2Config program.
Genesis II Installation Instructions 4-1.6.2 Performing Initial Tests Because of the Genesis II System’s flexibility, the various configurations can be vastly different from each other. For this reason, it is not practical to provide detailed procedural instructions for performing initial tests that apply to all configurations. However, this paragraph describes the general methodology for performing the initial tests.
Genesis II Installation Instructions 4-1.6.4 Second Phase Testing Perform the second phase of initial tests of the system as follows: 1. Turn on operating power to the primary output circuits such as pilot relays, motor controllers and heat valves. 2. Ensure that operating power to plant machinery (compressors, fans, etc.) is turned off. 3. In the Simulation Mode, observing the CAUTION noted above, carefully adjust the controller’s input parameters.
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Genesis II Direct Digital Controller INSTALLATION INSTRUCTIONS Chapter 5 - Network Installation
Genesis II Installation Instructions 5-1 Overview Due to their flexibility, the Genesis II Direct Digital Controller and MPCII Mid Points Controller, and associated REMs, can be connected in any of several equipment configurations based on the system’s operational requirements. In the simplest configuration, a single digital controller unit acts as a standalone controller for the unit.
Genesis II Installation Instructions 5-2.1 Definitions 5-2.1.1 Net Comms Net Comms provides a means to configure or monitor Digital Controllers from a PC at a speed of 57,600 (default) or 9,600 baud rates.
Genesis II Installation Instructions 5-3 Installation It is not possible to cover all the situations that may be encountered in the wide range of installations found in the field. The following examples are provided as a guide to assist in deciding the best method of connection for a Genesis II System Installation. Some situations require additional care to avoid hazardous situations.
Genesis II Installation Instructions Any cable that meets or exceeds all the stated specifications is suitable for use: • 2 twisted pairs • Minimum conductor cross section AWG24 (0.205 mm2) • Stranded core type is recommended (7 strands of 0.193 mm) • Conductor Foil screened cable with a wire drain • Less than 50 pf capacitance per metre between conductors • Less than 80 pf capacitance per metre between conductors and screen • Impedance 100 – 120 Ohms • Sheath thickness 0.
Genesis II Installation Instructions 5-3.3.1 Adding Modules to the Comms Link To insert another module into the Comms link, make a looping connection through it as in Example A of Figure 5-2 below. Alternatively, use a Innotech Repeater IR11 or IR12 to branch off to the new module as in Example B of Figure 5-2. Note that the four devices and Port 1 of the Repeater Module are connected in bus topology.
Genesis II Installation Instructions 5-3.3.3 Innotech Repeater IR11 on a REM Network The Innotech Repeater IR11 is a single channel repeater designed to expand a Sub System Network or REM network. It runs off either a 24VAC or DC power supply. A typical example of how the IR11 can be incorporated into an Sub System Network or REM network is given in Figure 5-3. 5-3.3.
Genesis II Installation Instructions 5-3.3.5 Multiple Network Arrangement Figure 5-4 shows a multiple network arrangement consisting, effectively, of four separate networks. Each is wired in a bus topology and each could be up to 400 metres long (at the default 57,600 Baud Rate) or 1,000 metres long (at the optional 9,600 Baud Rate). The networks are linked by the electronics in the Innotech Repeater IR12 module.
Genesis II Installation Instructions Example Figure 5-6: This example shows a Genesis II Direct Digital Controller with a network of REMs and an Innotech Repeater IR11 fitted. Once a Repeater is installed there are effectively two individual networks and each must have their EOL jumpers fitted as required, as illustrated at Example 1 in Figure 5-5. NOTE Both ends must have EOL jumpers fitted.
Genesis II Installation Instructions Example Figure 5-8: This example shows a Genesis II Direct Digital Controller with a network of REMs, where there is a Innotech Repeater IR11 located in the middle of a run. NOTE The Innotech Repeater IR11 has the EOL jumper fitted on Port 1 but not Port 2. Figure 5-8: REM Network with Innotech Repeater IR11 in the middle of a run 5-3.
Genesis II Installation Instructions NOTE The maximum possible number of devices on one section of cable is 31. Through the use of Innotech Repeaters, the maximum Genesis II System Devices allowed on a network is 128.
Genesis II Installation Instructions 5-3.5.2 Continuous Screen The screen on a primary network needs to be continuous. That means it remains unbroken along its entire length. As there is one ‘S’ terminal on a typical primary network device both the Global and Net screens are to be connected to this tie terminal. Refer to Figure 5-10 and Figure 5-11 for examples of Genesis II Direct Digital Controller / MPCII Mid Points Controller Comms Terminal connections. 5-3.5.
Genesis II Installation Instructions When other controllers ,such as Viewports or converters, are added to the Primary Network they must be installed in a manner that does not interrupt the integrity of the Primary Network. A lot of current devices will have the soft earth option and are fully isolated from the factory. There is no issue mixing the current style earth connection with previous models of hardware on the Primary Network if the following rules are applied.
Genesis II Installation Instructions 5-3.5.4 Innotech Repeater Modules The Innotech Repeater modules IR11 and IR12 (Figure 5-12) can be used with both the Genesis II Direct Digital Controller and MPCII Mid Points Controller. The repeater’s function is to rebuild each data byte before retransmitting it. When a repeater is added to a network it effectively creates two separate networks.
Genesis II Installation Instructions Neither the Innotech Repeater IR11 or IR12 have a separate earth terminal as it is a 24VAC powered device; however, the 24 V supply must be earthed on the 0 V side for safety and to make use of the Soft Earth feature. The IR12 is the current dual channel and dual baud rate repeater. The IR11 is the current single channel dual baud rate repeater. The IR12 and IR11 are fully isolated and both Port 1 and Port 2 offer the same level of protection.
Genesis II Installation Instructions Figure 5-14: GENII MPI Modem and Printer Interface Edition 2.
Genesis II Installation Instructions CAUTION Section 5-3.5.6 below, and their referenced figures, describe improper earth connection condition that could lead to severe electrical shock damage to equipment. Read and understand these paragraphs thoroughly before making any comms connections. 5-3.5.6 Hazardous Earth Connections When the Digital Controllers are supplied and earthed from two different switchboards, a hazardous situation can be created.
Genesis II Installation Instructions Figure 5-16 below 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.
Genesis II Installation Instructions 5-3.5.7 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.
Genesis II Installation Instructions 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 5-18 below. Figure 5-18: Use of GenII MPI, Circuit 2 Edition 2.
Genesis II Installation Instructions 5-4 Cable Connection Procedures This paragraph contains general procedures for the connection of Comms cables and checks to ensure there are no hazardous voltages present. The ideal situation would be that the voltages measured between the data conductors, between the data conductors and the screen and between the data conductors, the screen and the earthed parts of a device were 0VAC and 0VDC. In practice this will not be the case.
Genesis II Installation Instructions 3.5 V AC V DC 3.5 V AC V DC Isolated or Non-Isolated Genesis II Digital Controller SEE NOTES 1 and 2 1 2 3 20 21 24V 0 Earth Screen 3.5 V AC V DC RS-485 Ne t + - + C - Global 90 91 92 93 94 Results of this test should be NOTES as low as possible to ensure 1. Measure AC and DC voltages: error free communications Should be less than 3.5Vac and between +10Vdc and -5Vdc. 2. Measure voltages to the Screen connectors.
Genesis II Installation Instructions Comms Cables for Port 1 3.5V V AC V DC Measure AC and DC voltages: Should be less than 3.5Vac and between +10Vdc and -5Vdc. Isolated from internal circui t 2 24V V AC V DC Measure AC and DC voltages: Should be less than 24Vac and between +33Vdc and -33Vdc.
Innotech Support Innotech provides technical information on the Web to assist you with using its products. At www.innotech.com.au, you can find technical manuals, user instructions, and data sheets for all our products. For direct product support or product information, contact your local distributor, or an Innotech representative. You can contact us via email, fax, or postal mail: Website: Email: Fax: Mail: www.innotech.com.au sales@innotech.com.au +61 7 3421 9101 Innotech Control Systems P.O.
