Thermon Genesis TCM18 Retrofit: Bill of Materials and Equipment Layout
System Overview
This document details the Bill of Materials, equipment layout, and schematic diagrams for the Thermon Genesis TCM18 Retrofit system, designed to manage 72 circuits.
Bill of Materials
| POS QTY | ITEM NO | MANUFACTURER | CATALOG NUMBER | DESCRIPTION | |
|---|---|---|---|---|---|
| 14 | 1 | HOFFMAN | A-NADFK-MOD | ENCLOSURE, SWING PANEL MOUNTING KIT WITH QUARTER TURN LATCHES, PER THERMON DWG 49A14 REVC | |
| 20 | 1 | EXM | 171370 | 3" X 27" BACKPANEL WITH CUTOUT SAME AS 191181, WITH CUSTOM CUTOUTS FOR THE RETROFIT KIT | |
| 21 | 2 | THERMON | 21 | EVO DCM MOUNTING PLATE | |
| 25 | 2 | THERMON | 171340 | HMI MOUNT MASKING PLATE | |
| 71 | 1 | THERMON | 270701 | 18"X12" ALUMINUM PLATE WITH MOUNTING HOLES | |
| 82 | 1 | TENAQUIP | LAR482 | LASER-CUT 2.9" X 8.7" (73.1MM X 221.5MM) FLAT, WITH THREE MOUNTING HOLES | |
| 83 | 1 | THERMON | 27805 | TAG, CABINET, PLASTIC (TEXTURED), WHITE WITH BLACK LETTERS, 2" (51MM) X 6" (152MM) | |
| 100 | 1 | THERMON | 81040 | TAG, ATTENTION, 3" (76MM) X 5" (127MM) YELLOW WITH BLACK LETTERS, CHECK WIRE CONNECTIONS BEFORE ENERGIZING | |
| 120 | 1 | PHOENIX | 17573 | LABEL GENESIS DUO EVO | |
| 130 | 12 | THERMON | 81060 | GENESIS TOUCH SCREEN INTERFACE ASSEMBLY | |
| 137 | 1 | MOXA | MGATE MB3170-T | INDUSTRIAL DEVICE SERVER, 1 PORT RS-232/422/485, MODBUS TCP TO MODBUS SERIAL/ASCII/RTU, CLASS 1 DIV 2, DIN RAIL, 15KV SURGE, -40 TO 75°C | |
| 140 | 1 | THERMON | 81070 | GENESIS, INTERFACE BOARD, SIX RTD INPUTS (AKA "DTM6") | |
| 141 | 1 | THERMON | 81403 | GENESIS BRIDGE - PANEL MOUNT KIT | |
| 288 | 1 | PHOENIX | 37088 | UT 4-L/HESI | FUSE TB SECTION, DUAL LEVEL 30 AMP, 250V ACCEPTS 0.14 MM2 (#26 AWG) TO 6 MM2 (#10 AWG) WIRE |
| 291 | 1 | LITTELFUSE | 02153.15HXP | FUSE, CERAMIC, 3.15 AMP, 250 VAC | |
| 310 | 12 | THERMON | 810530 | GENESIS, 6 CIRCUIT, DISTRIBUTED CONTROL MODULE | |
| 323 | 1 | PHOENIX | PLC-RSC-24DC/21/EX | RELAY, SPDT, 6 AMP CONTACTS AT 250 VAC/DC, 24 VDC COIL, RATED FOR CLASS 1 DIV 2 / ZONE 2 AREA | |
| 400 | 2 | IBOCO | 3FD | TRACK, DIN MOUNTING, LOW PROFILE, 2 METER LENGTH | |
| 471 | 10 | PHOENIX | UT 2.5 | TERMINAL BLOCK SECTION, 24 AMP, 600 VAC, ACCEPTS, 0.14 MM2 (#26 AWG) TO 4 MM2 (#12 AWG) WIRE | |
| 476 | 1 | PHOENIX | UT 2.5-PE | TERMINAL BLOCK SECTION, UNIVERSAL GROUND, 600 VAC, ACCEPTS, 0.14 MM2 (#26 AWG) TO 4 MM2 (#12 AWG) WIRE | |
| 480 | 11 | PHOENIX | 3032350/CLIP FIX 35-5 | TERMINAL BLOCK END CLAMP | |
| 481 | 2 | PHOENIX | D-UT2.5/10 | END COVER - D-UT 2.5/10 FOR EARTHTERMINAL. | |
| 760 | 2 | ANIXTER | 440781 | WIRE, #16 AWG, ONE PAIR, BLACK/RED, STRANDED COPPER, SHIELDED, 600 VAC, UL, CSA | |
| 761 | 6 | ANIXTER | 440815 | WIRE, #14 AWG (2.1MM2), STRANDED COPPER, YELLOW, 600V, CSA TEW (105C), UL AWM (105C), AND UL MTW (90C) | |
| 761 | 2 | ANIXTER | 440811 | WIRE, #14 AWG (2.1MM2), STRANDED COPPER, BLACK, 600V, CSA TEW (105C), UL AWM (105C), AND UL MTW (90C) | |
| 761 | 2 | ANIXTER | 440813 | WIRE, #14 AWG (2.1MM2), STRANDED COPPER, WHITE, 600V, CSA TEW (105C), UL AWM (105C), AND UL MTW (90C) | |
| 761 | 2 | ANIXTER | 44314 | WIRE, #14 AWG (2.1MM2), STRANDED COPPER, GREEN, 600V, CSA TEW (105C), UL AWM (105C), AND UL MTW (90C) | |
| 762 | 6 | ANIXTER | 44550 | WIRE, #8 AWG (8.4MM2), STRANDED COPPER, GRN/YEL, 600, CSA TEW (105C), UL AWM (105C), AND UL MTW (90C) | |
| 769 | 50 | ALPHA WIRE | 5004C | 22-4C STR TNC PVC JKT CM 105C 300V AWM 80C 300V | |
| 777 | 1 | CABLESANDKITS | PC6AS-BL-03 | CAT6A, SHIELDED-COPPER ETHERNET PATCH CABLE, RJ45-RJ45, BOOTED, BLUE, 1 METER (3.28 FT.) |
Panel Layout and Views
The system is housed within a swing-out panel, featuring front and reverse views that illustrate component placement.
Front View
The front view (approximately 33.0" [838.2mm] height x 27.0" [685.8mm] width) shows the arrangement of components including the HMI, power supply, various terminal blocks (e.g., DTM, DCM, FUSE TB), and other interface modules. An "ATTENTION" label is present, advising users to check wire connections before energizing.
Reverse View
The reverse view provides a similar layout perspective, highlighting the DTMs and Power/CAN cable connections, which are shipped separately.
System Schematics and Connectivity
The schematics illustrate the electrical connections for the Genesis TCM18 retrofit system.
Power Distribution
A 100-240VAC control power input is supplied to a Quint-PS/1AC/24DC/5 power supply (PS), which outputs 24VDC. This 24VDC is distributed throughout the system to various modules.
Communication Network
The system utilizes a MOXA MGATE MB3170-T Ethernet converter to bridge Ethernet and RS-485 communication. An RS-485 connection is established to existing TCM18 terminals. A CAN bus network connects the Distributed Control Modules (DCMs) and Device Temperature Modules (DTMs). The Genesis Bridge (GB) and Interface Output Module (IOM) also integrate into the communication infrastructure.
Key Components and Modules
- Power Supply (PS): QUINT-PS/1AC/24DC/5, converts 100-240VAC to 24VDC.
- Ethernet Converter: MOXA MGATE MB3170-T, facilitates communication between Ethernet and RS-485.
- Genesis Bridge (GB): Interface module for system communication.
- Human-Machine Interface (HMI): Provides user interaction and display.
- Interface Output Module (IOM): Handles system alarm outputs.
- Distributed Control Modules (DCMs): DCM1 through DCM12 are connected via ribbon cables to a power module. They receive +24V, CANH, CANL, and GND.
- Device Temperature Modules (DTMs): DTM1 through DTM12 are designed to interface with RTD sensors. Each DTM connects to the CAN bus (CANH, CANL) and receives +24V power and GND. Across all DTMs, they support RTD #1 to RTD #72.
Wiring and Component Notes
- Wire Torque Specifications: Field power wiring requires minimum 75°C copper conductors. RTD input terminations (UT-2.5/UT-4, UT-6/UT-10/UK-16) have specific torque requirements (5.3-7.0 lbf-in for UT-2.5/UT-4, 13.2-15.9 lbf-in for UT-6/UT-10/UK-16).
- Fuse Replacement: F1 is a 5x20mm Ceramic 3.15A, 250V fuse. Replacement fuses must match type and rating.
