Thermon Genesis HMI Programming & Overview

Purpose:

This knowledge base serves as a comprehensive overview of all settings and programming capabilities available on the Genesis HMI (Human-Machine Interface). It provides users with detailed information and instructions to effectively navigate and utilize the features of the Genesis HMI for optimal performance and functionality.

Note:

Setting up a new Genesis Controller from scratch or during commissioning requires the use of the Genesis Sync (Tracenet Sync) application. This task cannot be completed solely on the panel HMI.

Similarly, when replacing or adding a new component to the Genesis control panel, the Genesis Sync (Tracenet Sync) application is necessary. Completing this activity solely on the panel HMI is not possible.

Genesis Controller HMI Screens

Circuit Overview Page

Get a quick snapshot of all circuits with a single glance, focusing on one circuit at a time for more detailed insight. Each dot encircling the selector dial represents a circuit, starting with Circuit 1 at the top and numbering ascending clockwise.

Red dots: Alarmed circuits.
Yellow dots: Alarms acknowledged.
Green dots: Active circuits without alarms.
Grey dots: Inactive circuits.

To navigate between circuits:

Tap the circuit dot.
Drag the black selector around the dial.
Use the arrows flanking the circuit number.

The center of the dial showcases the highlighted circuit's live temperature, target temperature, circuit name, and on-off duty cycle. Tap anywhere inside the dial to access the dashboard for that circuit.

For circuits set for ambient control, a slightly different view emphasizes electrical current (amps) rather than current temperature. To switch to ambient control display, you need to identify the assigned ambient RTD through the RTD list in Global Settings.

Circuit Details - Circuit Programming - Dashboard

Experience a detailed view of individual circuits on the dashboard, featuring:

Circuit number, tag, pipeline number, or other status.
Real-time data on temperature, heater current, and ground leakage current.
Alarm set points for quick reference.

Access this screen by tapping a circuit in the Overview or the Circuit List. The limits specified below outline the range of acceptable values. (These boundaries ensure valid settings, e.g., maintain temperature should not fall below the low temperature alarm threshold.)

Quick Programming:

Easily program the following setting simply by clicking the values from the Overview Screen

Temperature:
- High Trip
- High Alarm
- Low Alarm
Maintain Temperature
- Max Temp/Control Band
Heater Current
- Low Alarm
- High Alarm/Trip
Ground Current
- Alarm/Trip
Alarm Details

Alarm Type	Description
RTD Fault Alarm	This alarm triggers when the RTD reading falls outside the acceptable range, indicated by a resistance value exceeding 313.7 Ohms or dropping below 48.46 Ohms. It suggests potential issues like an unconnected or faulty RTD.
Low Temperature Alarm	When the temperature on a circuit dips below the programmed threshold, this alarm activates. It automatically clears once the temperature rises back to normal.
High Temperature Alarm	Conversely, this alarm alerts when the temperature exceeds the set maximum. Similar to the low temp alarm, it clears once conditions return to normal.
High-High Temperature (Option Trip)	If temperatures soar beyond a preset limit, this alarm is triggered. Acknowledging the alarm and cooling the temperature below the threshold are necessary to re-energize the circuit. Enabling the trip option changes the alarm color to orange; otherwise, it clears automatically.
Ground Current High Alarm	Excessive ground/earth leakage current prompts this alarm. It clears once the high leakage current event subsides.
Ground Current High-High Alarm (Option Trip)	Similar to temperature, this alarm signifies extremely high ground/earth leakage current. Acknowledging the alarm and reducing the current below the threshold are essential for circuit re-energization.
Low Current Alarm	When circuit amperage drops below the acceptable level, this alarm triggers.
High Current Alarm	Conversely, this alarm activates when circuit amperage exceeds the maximum threshold. It clears automatically once current levels normalize.
High-High Current (Option Trip)	If current exceeds the preset limit, this alarm is triggered. Acknowledgment and reducing current below the threshold are necessary for re-energization. Enabling the trip option changes the alarm color to orange; otherwise, it clears automatically.
Circuit Fault Alarm	This alarm suggests potential circuit issues, including CAN bus communication interruption, damaged DCM board, or anomalies during the SELF-TEST procedure.
Ground Fault Alarm	During a TEST-TO-TRIP procedure, this alarm indicates a failure to sense test leakage current, signaling a ground fault condition.
Programming Error	This warning highlights conflicts in programmed values for temperature, current, and ground current. Properly setting the values ensures correct functionality. Note that despite this error, circuits may still activate, emphasizing the importance of addressing programming discrepancies promptly.

Circuit Details - Circuit Programming - Circuit Settings

Per-Circuit Settings:

In this section, you'll find settings tailored to individual circuits, separate from general set points. Here, you can configure trip enabling assignments along with specifying the number and address of RTDs.

Setting	Description	Available Options	Lower Limit	Upper Limit	Units
Circuit Name	User defined Alpha-numeric Identifier unique to circuit	Alpha-numeric, Upper/ Lower Case, hyphen, dot	1	50	Characters
Process Tag	User defined alpha-numeric
Identifier For Grouping Circuits Together By Associated Process	Alpha-numeric, Upper/Lower Case, hyphen, dot	1		Characters
Active Alarm	Hexadecimal code for active alarms and a button to display and acknowledge active alarms	Acknowledge individual alarms or acknowledge all alarms	0x0000	0xFFFF
Alarm Acknowledge	Hexadecimal code for active alarms and a button to display and acknowledge active alarms	Acknowledge individual alarms or acknowledge all alarms • When all alarms are acknowledged the alarm relay will reset regardless of the alarm condition	0x0000	0xFFFF
High Trip Settings	Enable or disable buttons for Temperature, Current and Ground Current trips	Enable/Disable • When a trip is enabled the alarm must be acknowledged to reset the circuit
Control Type	Chose control method for circuit	On/Off, On/Off with Soft-Start, Proportional, Ambient Proportional Control
RTD Fault₉	Chose the forced duty cycle in the event of an RTD Fault	Number	0	100	%
Power Clamp₁₀	Maximum duty cycle allowed on circuit • Does not apply for Mechanical Relay	Number	0	100	%
Times The Heater Has Cycled₁₁	Cycle count for mechanical relay controlled by circuit	Number; read-only	0	2,147,483,648	Since Commissioning
Heater Relay Type	Displays mechanical or solid- state relays	Mechanical/SSR		Fixed at panel shop
Heater Voltage₁₂	Voltage provided to trace heater from relay(s)	Number	0	Fixed at panel shop	Volts
Heater Amp Hour Accumulation	Running total of Amp Hours accumulated since last reset of value	Number	0	2,147,483,648
Heater Watt Hour Accumulation₁₃	Running total of Watts accumulated since last reset of value	Number	0	2,147,483,648	Watts
Time Heater Will Come Back On	Applies to APCM; time left until the heater switches on again within 20 minute window	Number	0	20	Minutes
Ground Current Reading At Trip	Ground fault current reading that caused most recent trip	Number	20	255	mA
Heater Current Reading At High Current Trip	Heater current reading that caused most recent trip	Number	1	100	A
DCM Address	Address (displayed on each board) unique to each board that allows communication between modules	Fixed number between 01-20	1	Fixed at panel shop

Notes:
9. RTD FAULT ALARM An RTD reading is out of range when the resistance exceeds 313 Ω or is less than 48 Ω. In either case, the RTD has been damaged or has been disconnected in service. NOTE: The Genesis Controller will continue to control if a second undamaged RTD is available. Otherwise, the default heater status is “De-energized”.
10. “Power Clamp” for Genesis Controller systems are available when the units are used with solid-state relays, and is enabled when a circuit is set for “on/off
with soft start”. This feature literally provides “soft start” using a reduced on/off duty time cycle of 1 second initiating at the percentage selected.

Example 1: Power Clamp of 20% is selected this results in an initial duty cycle of 0.2s “full on” and 0.8s off)
Example 2: “on/off with soft start” is selected with 100% Power Clamp. The result is that the circuit will operate in a normal on/off method.

11. This value can be reset with the Admin login after replacing relays.
12. The heat/voltage value is not measured by the Genesis Controller system. This value is fixed before panel shipment to match design and distribution voltage as constructed.
13. This value is calculated from supplied voltage and measured heater current.

Assigning RTDs to Circuits

Assigning RTDs to a circuit is a two-step process:

Step 1 - Configure RTDs in Global Settings:
1. RTDs need to be configured first in the global setting page using one of the following methods:
  a. Standard Control Mode – Control/Alarm/Trip
  b. Ambient - Control/Low Temp = DIS
  c. Monitor Mode 1 – Alarm/Trip
  d. Monitor Mode 2 – Trip
  e. Monitor Mode 3 - Alarm
  f. Monitor Mode 4 – Monitor Only
Step 2 - Assign RTDs in Circuit Settings:
1. Enter in the number of RTDs required for the circuit.
2. Enter the CANBUS ID or the DTM that holds the desired RTDs into the "DTM" field,
3. Enter in the RTD number (1-6) into the "RTD" field.

A single controller may have up to 20 RTDs assigned to it.

Circuit Details - Circuit History

Explore temperature and current data plotted over a span of up to six months, alongside recorded set point changes.

Circuit Details - ISO (Isometrics)

Easily inspect the circuit's isometric drawing (ISO) using multi-touch pinch and zoom gestures for a detailed view.

Alarm List

Access the Circuit Alarm List from the Menu. Here, live panes for each circuit in alarm are organized in a list with tabs for all alarms, categorized by alarm type, or by process. To acknowledge an alarm, simply tap "ACK" on the left of the circuit pane. A box will display each alarm for that circuit, allowing you to acknowledge individual alarms or all alarms for that circuit.

Main Menu

To access the Main Menu, simply tap the 'hamburger' icon located in the upper left corner of any screen. Use the Menu to effortlessly navigate between Overview, Circuit List, Global Settings, and the System screen. Additionally, you can switch between night and day color profiles and perform tasks like importing and exporting configurations, isometrics, and more.

Admin Login

To access administrator privileges, users will be prompted to log in when attempting to modify any setting or set-point. Alternatively, Admin Login can be selected from the Menu. Admin mode is denoted by a red tint and border surrounding all screens. After a valid password entry, the system remains in Admin Mode for 5 minutes, even during active circuit programming.

Note: The default "Admin Login" value is "abc123" (not case-sensitive). It's crucial to assign the "Admin Login" to the responsible Project Manager or Administrator overseeing the relevant process unit(s). This information should be securely stored but readily accessible in case of an emergency.

Global Settings:

Access Global Settings from the Menu. Here, you can configure system-wide settings such as Temperature Units and Start-up Delay, ensuring consistency across the entire system.

Setting	Description	Acceptable	Lower Limit	Upper Limit	Units
System Date and Time	Current Time and Date	Gregorian Calendar; 24 hr time; time zone offset from GMT
Language	Displayed system language	English (US), English (UK), Arabic, Chinese, Spanish, French, Japanese, Korean, Russian
Self Test Interval (Hrs)	Time in hours between automatically run self tests	Number	0	168	Hours
Max Current with Heater Off	Maximum current reading allowed when a heater is off before a circuit fault alarm is triggered	Number	0.5	5	A
Ground Fault Samples Before Trip	Number of ground current samples read above trip set point before trip is triggered. (does not affect time to trip because the samples are microseconds apart) This is to improve noise immunity.	Number	0	6
Start Up Delay	Time in minutes before heaters turn on for the first time after system power up. This allows users to stagger start up across many panels to reduce load step on plant power.	Number	0	30	Minutes
High Current Alarm Delay	Time in minutes to delay current alarms after high readings. This is to prevent nuisance alarms on startup current.	Number	0	7	Minutes
Temperature Delay Alarm	Time in minutes to delay temperature alarms. This is useful for avoiding nuisance alarms due to steam-out.	Number	0	30	Minutes
Ground Fault Loop Test	Runs self contained test to confirm integrity of the ground current measurement system.	Touch to Start
Self-Test	Runs self contained test including the ground fault loop test and additionally turns measures heater current with heater on and off to verify relay operation and current measurements.	Touch to Start
Mechanical Relay Duty Cycle Time	Duty cycle period for relays in proportional control mode.	20 Minutes			Minutes
DTM Temperature Units	Switch temperature units between Fahrenheit and Celsius	Fahrenheit, Celsius
Settings Poll Period in Minutes	Time in minutes between requests from HMI to modules for all system information	Number	5	20	Minutes
Selected Network	Switch between Onboard Ethernet (default) or USB (for use with USB-Ethernet adapter - diagnostics)	Onboard/USB
IP Address	Internet Protocol Address (see network administrator for IP Address assignments)	IPv4 Address	0.0.0.0	255.255.255.255
Subnet Mask	Binary mask which defines the subnetwork to which a device belongs (see network administrator for Subnet Mask assignments)		0.0.0.0	255.255.255.255
Gateway IP	First networking device connected to on the network (see network administrator for Gateway IP assignments)	IPv4 Address	0.0.0.0	255.255.255.255
Admin Password	Password used to protect the system from unintended or unauthorized changes	Alpha-numeric 50 character limit
Number of Ambient RTDs	Sets the number of ambient RTD sensors used by the system	Number	0	6
Mapped Ambient RTD#	Address and Subaddress of the assigned RTD; the number of "Mapped Ambient RTD#" fields corresponds to the "Number of Ambient RTDs" value, i.e. if "Number of Ambient RTDs" is set to 3, there will be 3 "Mapped Ambient RTD#" fields to provide an address for each RTD	DTM: number 1-99; RTD: Number 1-6

System Menu:

The System section offers tools for updating system software and firmware, displaying the current installed version. By selecting the "Mount USB Drive" button, users can access a list of all Genesis Controller modules, along with their respective addresses and firmware versions. Access to this section requires Admin Login for security purposes.