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Advantage Controls MegaTron Training

Advantage Controls MegaTron Training. Presented by:. Megatron Capabilities. Megatron controllers are capable of controlling up to four independent systems. Mix or match: Cooling Towers Boilers Closed Loops Process Streams Commercial Pools/Spas All in a single unit!. Megatron Display.

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Advantage Controls MegaTron Training

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  1. Advantage ControlsMegaTron Training Presented by:

  2. Megatron Capabilities Megatron controllers are capable of controlling up to four independent systems. Mix or match: • Cooling Towers • Boilers • Closed Loops • Process Streams • Commercial Pools/Spas All in a single unit!

  3. Megatron Display 16-line backlit LCD display (240x128 pixels) • Capable of displaying graphical data • Unique white characters on blue background • Fully customizable unit, system, and relay names

  4. Megatron Interface ATM-style programming • 20-button keypad • Logical, easy-to-program • On-screen instructions

  5. Security Megatron controllers feature 3 password levels: • User - permission to change certain settings can be granted or denied (i.e., calibration, setpoints, relay activation, etc.) • Administrator - access permitted to almost all programming • Factory - unlocks upgrades, new features, and top-level programming

  6. Relay Outputs MegaTron controllers can be equipped with up to 20 120V or dry contact relay outputs (5 per card) • Relays are 2.5 amp, individually fused • Relays are field-assignable to any control function or alarm condition • More than 10 relays requires a secondary enclosure • Units come pre-wired standard (conduit available)

  7. Agency Approval All MegaTrons are stamped with the ETL safety approval (UL/CSA standards) • High voltage and low voltage connections are separated be a physical panel divider • Each relay card (5 relays) requires a separate male power cord

  8. Sensor Inputs Each system card can monitor and control: • Conductivity • Temperature • pH • ORP • Makeup conductivity/cycles • Makeup temperature

  9. Sensor Inputs Boiler Conductivity: • Ryton with 1” MNPT SS bushing • All stainless body • SS electrode tips • Temperature compensation • RTD (fast & accurate) • Thermistor • None Cooling Tower Conductivity: • PVC with 3/4” tee • PVC with 1” MNPT SS bushing • PVC with 1” quick-disconnect fitting for makeup lines • Tank mount (18” PVC) • Carbon or SS electrode tip choices

  10. Sensor Inputs ORP: • 3/4” PVC tee (140*F) • 3/4” CPVC tee (180*F) • Tank mount (36” PVC) • With or without pre-amp pH: • 3/4” PVC tee (140*F) • 3/4” CPVC tee (180*F) • Tank mount (36” PVC) • Stainless steel (212*F) 1/2” MNPT body • With or without pre-amp

  11. Digital Inputs Each system card can be equipped with: • 2 water meter inputs included when a feed timer is ordered (makeup and bleed-off) • Compatible with contacting head or paddlewheel style water meters • 5 low drum level inputs (single point) • 1 flow switch input (thermal or mechanical)

  12. Feed Verification Inputs MegaTron controllers can be equipped with up to 9 FloTracker feed verification inputs • Measure and totalize chemical feed volume • Alarm on loss of prime • Adjust feed settings in terms of chemical volume • Track remaining chemical inventory • Calculate PPM of inhibitors in the system

  13. 4-20 mA Inputs/Outputs Megatrons can be equipped with: • Eight 4-20 mA inputs • Six 4-20 mA outputs 4-20 mA inputs can take a signal from any 4-20 mA source such as ClO2 probes, corrosion rate monitors, continuous drum level monitors, etc. 4-20 mA outputs can be assigned to any analog input including any probe or 4-20 mA input

  14. Taggable Timers All feed timers are field-selectable from: • Pulse timer (water meter actuated) • Feed with bleed (limit timer) • Feed after bleed (% of bleed off with limit) • Percent timer (selectable cycle and % on time) • 28-day biocide (4 independent schedules per timer)

  15. I/O Summary MegaTron controllers can be equipped with: • 32 analog inputs • 24 sensors (limited to 4 of each type) • 8 4-20 mA signals • 32 digital inputs • 8 water meters • 20 drum level switches • 4 flow switch or stop inputs • 9 feed verification inputs • 20 relay outputs (16 NO/NC) • 6 analog (4-20 mA) output signals

  16. On-Board History Megatron controllers automatically store the following data for on-screen display in graphical or data log format: • Sensor inputs (conductivity, pH, ORP, temp, etc.) • 4-20 mA inputs • Water meters (makeup, bleed-off, evaporation) • Chemical volume usage • Relay activity • Alarm conditions • Keypad activity (snoop alert) Maximum amount of stored data depends on the number of monitored parameters and the frequency of monitoring.

  17. Notepad Keep track of all service report data using the integrated “Notepad” feature • Choose from 21 defined tests such as hardness, alkalinity, chlorides, etc. - or create your own custom test parameters • Generate on-screen graphs or logs of historical service report data to gauge overall program effectiveness • Optional LSI/RSI for units with pH control

  18. Notepad Sample Notepad entry:

  19. Capabilities Quiz • Maximum number of MegaTron relays? • Maximum number of pH probes in a single unit? • Number of security (password) levels? • Number of water meter inputs per system card? • Number of feed timer modes? Name them…. • A 12-relay controller will have how many male power cords? Why? • Can a single system card contain conductivity, makeup conductivity, pH, and ORP?

  20. Specification / Model Numbering To build your MegaTron model number, start with MG, then add: • Option codes for the first system • Option codes for each additional system (or -X2, -X3, etc. if additional systems are identical) • Whole unit option codes (communications, 4-20mA, expansion buses, extra relays, etc.)

  21. System Pricing To determine the list price of a MegaTron controller: • Start with the base list price (only add once) • Add the option prices for each system control feature • each probe input • each timer • each flow switch & level input • Add the option prices for the “whole unit” options • Kick back and enjoy the savings!

  22. Specification / Model Numbering Example #1: Build and price the following MegaTron: • Single tower system • Conductivity, pH, and ORP control • 2 feed timers • Flow switch assembly • Internet communications card (Ethernet) ………………...

  23. Specification / Model Numbering Example #1: Build and price the following MegaTron: • Single tower system • Conductivity, pH, and ORP control • 2 feed timers • Flow switch assembly • Internet communications card (Ethernet) Model number = MGCPRF2E-H1 List price = $4369

  24. Specification / Model Numbering Example #2: Build and price the following MegaTron: • Dual boiler system • Conductivity control for each boiler using standard boiler probes • 2 total feed timers (common feedwater tank) • Capability to add conductivity control to a third boiler at a later date (requires expansion slots and an extra control relay) ………………...

  25. Specification / Model Numbering Example #2: Build and price the following MegaTron: • Dual boiler system • Conductivity control for each boiler using RTD-style boiler probes • 2 total feed timers (common feedwater tank) • Capability to add an extra boiler system and remote communications at a later date (requires expansion slots and an extra control relay) Model number = MGB1F2-B1-GK List price = $3100

  26. Megatron Interface By the end of this session, you should be able to: • Navigate the MegaTron menu structure • Program the core functions of a MegaTron

  27. Megatron Interface SETUP/RUN - toggles between setup and run modes HOME - takes you to the home setup page from any sub-menu ENTER - saves changes made to dialog box entries CANCEL - aborts changes made to dialog box entries BACK - takes you to previous menu; erases last entry in dialog boxes HELP - provides help tips from any setup menu; fast forwards through alpha-numeric text entries ARROWS - up & down scroll through dialog box choices; left & right move cursor in dialog boxes or change the operation of selective functions (i.e., rising/falling setpoint) NUMBERS - access menus ATM-style; enter numeric values for all programming

  28. Menu Structure The Megatron home setup page is divided into 10 major submenus: • SETPOINTS • CALIBRATION • TIMERS • CUSTOMIZE • ALARMS • DATE/TIME • CONFIGURE • HISTORY • WATER METER • RELAYS

  29. Setpoints Menu The SETPOINTS menu allows you to change setpoints and alarms levels for all analog inputs (probe & 4-20 mA). • Setpoint = relay “on” point • rising: conductivity, acid feed • falling: ORP, caustic feed, closed loop treatment • Differential = required movement away from the setpoint before deactivating the relay (aka: deadband or hysteresis) • High & low alarms do not interrupt relays. • Limit time only interrupts pH or ORP relays.

  30. Setpoints Menu - Sampling Modes MegaTron controllers can utilize 3 different sampling methods. Method #1: • Continuous - Used when the probe will see a continuous water sample at all times (cooling towers or very large boilers). Controller will continuously monitor the water and control accordingly.

  31. Setpoints Menu - Sampling Modes Method #2: • Timed - Used only when intermittent sampling is desired (small to medium sized boilers). Controller will control the boiler water conductivity only after an active sample cycle (duration) and then remain inactive during the off-period (interval). Time initiates the control cycle, but the conductivity reading ends it.

  32. Setpoints Menu - Sampling Modes Method #3: • Sample & Hold - Similar to timed sampling with the addition of a “hold” period to allow steam to settle in a line before reading the water sample. Controller will alternate between “hold” and “blowdown” periods until conductivity setpoint is satisfied.

  33. Calibration Menu The CALIBRATION menu allows you to make calibration adjustments to all analog inputs (probe or 4-20 mA): • One point = check hand tester and correct the MegaTron’s reading • Two point = calibrate against two different standards (or zero the probe for conductivity) • Not necessary to calibrate ORP (it is what it is)

  34. Timers Menu The TIMERS menu allows you to select the timer type and activation settings for all taggable timers. • Pulse (water meter must also be programmed) • Percent (good for low dosage, repeated feed throughout the day - some biocides) • With-bleed • Post-bleed • 28-day (can be interlocked with ORP to feed to an ORP setpoint only at certain times of the week)

  35. Customize Menu The CUSTOMIZE menu allows you to customize the on-screen names of: • Megatron unit • Systems • Relays • Notepad (name, measurement units, alarm levels) • pH index (LSI or RSI) • 4-20 mA inputs (name, measurement units)

  36. Alarms Menu The ALARMS menu provides a complete listing of all current alarms for each individual control system. Date/Time Menu The DATE/TIME menu allows you to set the controller’s current date, time, day of week, and week number.

  37. Configure Menu The CONFIGURE menu allows you to change: • Passwords • Admin = full access (except “factory” settings) • User = access restricted to defined areas • Relay assignment • change which function controls which relay • History resolution & alarm delay • Display contrast • Network settings (covered in more detail later) • Factory-level settings (several submenus deep)

  38. History Menu The HISTORY menu allows you to view: • Sensor history - conductivity, pH, ORP, temp. • Relay logs - time stamp for each on/off activation • Alarm logs - time stamp for each alarm condition • Event logs - time stamp for keyboard activity • Notepad history - all user-entered test data • Water meter - makeup, bleed-off, evaporation

  39. Totalizers Menu The TOTALIZERS menu allows you to adjust the contact value of water meters and feed verification devices (must be programmed to utilize water meter actuated feed or chemical volume feed calcuations) Relays Menu The RELAYS menu allows you to view: • Relay name and functional assignment • Relay status (forced on, forced off, or auto) • Totalized relay on-time and date of last reset

  40. Programming Test #1 Setup a System #1 as a cooling tower controller to perform the following: • Maintain conductivity between 1300 and 1400uS. • Maintain pH between 7.5 and 7.8 and prevent acid overfeed by using a 45 minute feed limit timer. • Feed an oxidizing biocide to maintain an ORP residual of between 300 and 350mV (falling setpoint). • Use Timer 1 to feed inhibitor for 45 seconds for every 100 gallons of makeup water that enters the system (water meter #1). • Use Timer 2 to feed a non-oxidizing biocide every Monday, Wednesday, and Friday at 7:00 a.m (pre-bleed & lockout are optional).

  41. Programming Test #2 Program these additional settings into your cooling tower system: • Setup the extra timer to feed closed loop treatment using water meter #2 (2 minutes per 50 gallons). • Setup a user password that will prevent access to the calibration, setpoints, and timers menus.

  42. Programming Test #3 Setup System #2 to act as a boiler controller to perform the following: • Sample the boiler water every 3 hours for 1 minute and maintain conductivity between 3800 and 4000uS. • Setup a timer to add a boiler treatment for 2 minutes per 50 gallons of fresh makeup water introduced into the feedwater tank. • How many total relays will this 2-system controller utilize?

  43. Hardware Overview The MegaTron controller is divided into two main compartments: • Logic (top) - contains motherboard, system cards, communication card, low voltage wiring • Power (bottom) - contains power supply, relay cards, fuses, high voltage wiring These two compartments are physically separated by a panel divider.

  44. System Cards • System cards contain connections for probes, water meters, flow switches, and drum level inputs (22AWG wiring). • The card features a yellow status LED near the bottom. • The card plugs into a slot on the motherboard.

  45. Motherboard • Slot #1 is always communications. • Slot #2 is always System 1. • Other slot assignments will vary depending on configuration. • Incoming power connector is in the bottom left corner. • Relay card connections are in the bottom right corner. • Firmware can be updated by inserting a program card.

  46. Relay Cards • Relay cards contain 5 relays each. • Relays 2-5 can be NO/NC • Relay 1 is NO only, but can be set as a dry contact in the field by clipping a jumper. • Each relay is individually fused with a 2.5A fuse. • Each relay card has it’s own power input (bottom left connector) and logic input (top right ribbon cable).

  47. Field Upgrades With optional expansion buses, Megatrons can be upgraded with: • Additional system cards • Communications cards • 4-20 mA cards Extra control relays can be assigned as needed

  48. Adding New Cards Adding a new card to a MegaTron requires two steps: • Physically install the card and wiring connections • Activate the card and new functions through the “Factory” menu • Factory password is required (daily use only - resets to a new factory password on the following day)

  49. Unlocking New Features New programming features can be unlocked in the “factory” submenu using the factory password. • New cards, inputs/outputs, relays, timers, water meters, flow switches, level wands, etc. can all be enabled through software. • New features require the appropriate hardware (enabling pH through software does no good if the pH circuit isn’t available).

  50. Hardware Test Your MegaTron should have an unused relay. • Use this extra relay and unlock a new timer to feed a steam line treatment into your boiler system. • Program the new timer as you wish. • Consult the “cheat sheet” if necessary. • Bonus points - What is the complete model number of your upgraded MegaTron controller?

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