Presentation on theme: "Advantage Controls MegaTron Training"— Presentation transcript:
1 Advantage Controls MegaTron Training Presented by:
2 Megatron Capabilities By the end of this session, you should be able to:Understand the core capabilities and features of the MegaTron line of controllersSpecify the correct MegaTron model for you applicationDetermine the list price of a specified MegaTron
3 Megatron Capabilities Megatron controllers are capable of controlling up to four independent systems. Mix or match:Cooling TowersBoilersClosed LoopsProcess StreamsCommercial Pools/SpasAll in a single unit!
4 Megatron Display 16-line backlit LCD display (240x128 pixels) Capable of displaying graphical dataUnique white characters on blue backgroundFully customizable unit, system, and relay names
6 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 programmingFactory - unlocks upgrades, new features, and top-level programming
7 Relay OutputsMegaTron controllers can be equipped with up to V or dry contact relay outputs (5 per card)Relays are 2.5 amp, individually fusedRelays are field-assignable to any control function or alarm conditionMore than 10 relays requires a secondary enclosureUnits come pre-wired standard (conduit available)
8 Agency ApprovalAll MegaTrons are stamped with the ETL safety approval (UL/CSA standards)High voltage and low voltage connections are separated be a physical panel dividerEach relay card (5 relays) requires a separate male power cord
9 Sensor Inputs Each system card can monitor and control: Conductivity TemperaturepHORPMakeup conductivity/cyclesMakeup temperature
10 Sensor Inputs Cooling Tower Conductivity: Boiler Conductivity: PVC with 3/4” teePVC with 1” MNPT SS bushingPVC with 1” quick-disconnect fitting for makeup linesTank mount (18” PVC)Carbon or SS electrode tip choicesBoiler Conductivity:Ryton with 1” MNPT SS bushingAll stainless bodySS electrode tipsTemperature compensationRTD (fast & accurate)ThermistorNone
11 Sensor Inputs pH: ORP: 3/4” PVC tee (140*F) 3/4” PVC tee (140*F) 3/4” CPVC tee (180*F)Tank mount (36” PVC)Stainless steel (212*F) 1/2” MNPT bodyWith or without pre-ampORP:3/4” PVC tee (140*F)3/4” CPVC tee (180*F)Tank mount (36” PVC)With or without pre-amp
12 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 meters5 low drum level inputs (single point)1 flow switch input (thermal or mechanical)
13 Thermal Flow SwitchesMegatron controllers are compatible with our thermal flow switchesTFS use thermal sensors to detect flow statusTFS don’t use mechanical floatsTFS are resistant to debris in sample lineTFS minimize incorrect flow readings
14 Feed Verification Inputs MegaTron controllers can be equipped with up to 9 FloTracker feed verification inputsMeasure and totalize chemical feed volumeAlarm on loss of primeAdjust feed settings in terms of chemical volumeTrack remaining chemical inventoryCalculate PPM of inhibitors in the system
15 4-20 mA Inputs/Outputs Megatrons can be equipped with: Eight 4-20 mA inputsSix 4-20 mA outputs4-20 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
16 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)
17 I/O Summary MegaTron controllers can be equipped with: 32 analog inputs24 sensors (limited to 4 of each type)mA signals32 digital inputs8 water meters20 drum level switches4 flow switch or stop inputs9 feed verification inputs20 relay outputs (16 NO/NC)6 analog (4-20 mA) output signals
18 On-Board HistoryMegatron 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 inputsWater meters (makeup, bleed-off, evaporation)Chemical volume usageRelay activityAlarm conditionsKeypad activity (snoop alert)Maximum amount of stored data depends on the number of monitored parameters and the frequency of monitoring.
19 On-Board HistorySpecify the data and measurement range of your on-screen graphs:
20 NotepadKeep track of all service report data using the integrated “Notepad” featureChoose from 21 defined tests such as hardness, alkalinity, chlorides, etc. - or create your own custom test parametersGenerate on-screen graphs or logs of historical service report data to gauge overall program effectivenessOptional LSI/RSI for units with pH control
22 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?
23 Specification / Model Numbering To build your MegaTron model number, start with MG, then add:Option codes for the first systemOption 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.)
24 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 featureeach probe inputeach timereach flow switch & level inputAdd the option prices for the “whole unit” optionsKick back and enjoy the savings!
25 Specification / Model Numbering Example #1: Build and price the following MegaTron:Single tower systemConductivity, pH, and ORP control2 feed timersFlow switch assemblyInternet communications card (Ethernet)………………...
26 Specification / Model Numbering Example #1: Build and price the following MegaTron:Single tower systemConductivity, pH, and ORP control2 feed timersFlow switch assemblyInternet communications card (Ethernet)Model number = MGCPRF2E-H1List price = $4369
27 Specification / Model Numbering Example #2: Build and price the following MegaTron:Dual boiler systemConductivity control for each boiler using standard boiler probes2 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)………………...
28 Specification / Model Numbering Example #2: Build and price the following MegaTron:Dual boiler systemConductivity control for each boiler using RTD-style boiler probes2 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-GKList price = $3100
29 Specification / Model Numbering Example #3: Build and price the following MegaTron:3-tower systemConductivity and ORP control on each system2 feed timers on each systemThermal flow switch on each system4-20mA output for each probeCapability to add Internet communications in the future………………...
30 Specification / Model Numbering Example #3: Build and price the following MegaTron:3-tower systemConductivity and ORP control on each system2 feed timers on each systemThermal flow switch on each system4-20mA output for each probeCapability to add Internet communications in the futureModel number = MGCRF2E1-X3-HO4List price = $6200
31 Specification / Model Numbering Example #4: Build and price the following MegaTron:2-boiler system with condensate pH monitoring (common condensate line)Conductivity control for each boiler using RTD boiler probesCondensate monitoring using stainless steel pH probe3 total feed timers (common feedwater tank)Stop input on each boiler to prevent sampling when offline (think flow switch)Internet communications via cellular modem……………………
32 Specification / Model Numbering Example #4: Build and price the following MegaTron:2-boiler system with condensate pH monitoring (common condensate line)Conductivity control for each boiler using RTD boiler probesCondensate monitoring using stainless steel pH probe3 total feed timers (common feedwater tank)Stop input on each boiler to prevent sampling when offline (think flow switch)Internet communications via cellular modemModel number = MGB1F3E6-B1E6-P8-H3List price = $5141
33 Megatron Interface By the end of this session, you should be able to: Navigate the MegaTron menu structureProgram the core functions of a MegaTron
34 Megatron Interface SETUP/RUN - toggles between setup and run modes HOME - takes you to the home setup page from any sub-menuENTER - saves changes made to dialog box entriesCANCEL - aborts changes made to dialog box entriesBACK - takes you to previous menu; erases last entry in dialog boxesHELP - provides help tips from any setup menu; fast forwards through alpha-numeric text entriesARROWS - 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
35 Menu StructureThe Megatron home setup page is divided into 10 major submenus:SETPOINTSCALIBRATIONTIMERSCUSTOMIZEALARMSDATE/TIMECONFIGUREHISTORYWATER METERRELAYS
36 Setpoints MenuThe SETPOINTS menu allows you to change setpoints and alarms levels for all analog inputs (probe & 4-20 mA).Setpoint = relay “on” pointrising: conductivity, acid feedfalling: ORP, caustic feed, closed loop treatmentDifferential = 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.
37 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.
38 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.
39 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.
40 Calibration MenuThe 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 readingTwo point = calibrate against two different standards (or zero the probe for conductivity)Not necessary to calibrate ORP (it is what it is)
41 Timers MenuThe 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-bleedPost-bleed28-day (can be interlocked with ORP to feed to an ORP setpoint only at certain times of the week)
42 Customize MenuThe CUSTOMIZE menu allows you to customize the on-screen names of:Megatron unitSystemsRelaysNotepad (name, measurement units, alarm levels)pH index (LSI or RSI)4-20 mA inputs (name, measurement units)
43 Alarms Menu Date/Time Menu The ALARMS menu provides a complete listing of all current alarms for each individual control system.Date/Time MenuThe DATE/TIME menu allows you to set the controller’s current date, time, day of week, and week number.
44 Configure Menu The CONFIGURE menu allows you to change: Passwords Admin = full access (except “factory” settings)User = access restricted to defined areasRelay assignmentchange which function controls which relayHistory resolution & alarm delayDisplay contrastNetwork settings (covered in more detail later)Factory-level settings (several submenus deep)
45 History Menu The HISTORY menu allows you to view: Sensor history - conductivity, pH, ORP, temp.Relay logs - time stamp for each on/off activationAlarm logs - time stamp for each alarm conditionEvent logs - time stamp for keyboard activityNotepad history - all user-entered test dataWater meter - makeup, bleed-off, evaporation
46 Totalizers Menu Relays 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 MenuThe RELAYS menu allows you to view:Relay name and functional assignmentRelay status (forced on, forced off, or auto)Totalized relay on-time and date of last reset
47 Programming Test #1Setup 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).
48 Programming Test #2Program 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.
49 Programming Test #3Setup 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?
50 Megatron Hardware By the end of this session, you should be able to: Locate and identify the basic component parts of a MegaTron controllerUnderstand the field-upgrade processUtilize the factory password to unlock extra features
51 Hardware OverviewThe MegaTron controller is divided into two main compartments:Logic (top) - contains motherboard, system cards, communication card, low voltage wiringPower (bottom) - contains power supply, relay cards, fuses, high voltage wiringThese two compartments are physically separated by a panel divider.
52 System CardsSystem 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.
53 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.
54 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).
55 Field UpgradesWith optional expansion buses, Megatrons can be upgraded with:Additional system cardsCommunications cards4-20 mA cardsExtra control relays can be assigned as needed
56 Adding New Cards Adding a new card to a MegaTron requires two steps: Physically install the card and wiring connectionsActivate the card and new functions through the “Factory” menuFactory password is required (daily use only - resets to a new factory password on the following day)
57 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).
58 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?
59 MegaTron Communications By the end of this session, you should be able to:Understand the various communication formatsConnect to a MegaTron in both local and remote modesNavigate the WebAdvantage interfaceUnderstand the procedure for setting up automated summary reports
60 Connecting in Local Mode Connecting to a MegaTron in local mode allows you to:View real-time controller operating dataChange all controller settingsDownload data as a delimited text file for importing into ExcelLocal mode is best used for simply downloading data from the MegaTron to your laptop (not many bells & whistles).
61 Connecting in Local Mode To connect in local mode:Plug the MegaTron’s Ethernet cable into one end of the inline coupler (supplied), and then plug the cross-over cable (also supplied) into the other end of the coupler.Connect the cross-over cable to the Ethernet port on the back of your laptop (or PC).
62 Connecting in Local Mode To connect in local mode:Using the “Network Connections” function of your computer, modify you LAN connection TCP/IP properties, making sure that the last digit(s) of the “dotted quad” IP address is different than that of the MegaTron (see Network sub-menu in Configuration menu).Open a browser window and enter the IP address of the MegaTron.Connection complete!
63 Connecting in Local Mode Local mode snapshot:East Village Hospital
64 WebAdvantage Overview WebAdvantage is an Internet-based remote monitoring service that allows you to:View real-time controller operating dataChange all controller settingsGenerate custom graphs and data logsReceive automated summary reports viaReceive alarm conditions via
65 WebAdvantage Overview Megatron controllers are online all the time allowing for continual transmission of data to the WebAdvantage serversData is stored in duplicate on two servers to ensure it is always backed upWebAdvantage allows multiple users to connect to a controller simultaneouslyConstant connections allow a for a summary view of all controllers at once
66 WebAdvantage Requirements Before connecting to WebAdvantage, the following are required:Megatron with H1, H3, or H4 optionEthernet port, dedicated phone line, or SIM card from cellular providerFull-time Internet access (DSL, T1, dedicated dial-up, wireless plan)Internet browser with 128-bit encryptionLogin form supplied to ACI
68 RJ-45 Through EthernetPlug the supplied RJ-45 plug into an available CAT-5 Ethernet portUsing DHCP protocol, the Megatron communicates with the facility’s computer network to obtain outside Internet accessIf desired, the building’s network administrator may wish to assign a static IP address in lieu of using DHCPPros - easy setup, no extra ISP charge
69 Cellular Modem to Internet Insert the SIM card from your cellular provider into the cellular modem provided with the MegaTronConnect the external cellular antenna if necessaryMegaTron will automatically connect to the Internet using the settings pre-programmed on the SIM cardRequires an unlimited wireless data plan from a compatible provider (T-Mobile, Cingular)Use when no computer netowrk is available or when it is necessary to bypass the facility’s network
70 Dial-up Modem to Internet Plug the Megatron’s phone line cable into a dedicated phone jackProgram the MegaTron with the ISP login information supplied by your provider and the MegaTron will establish a connection with the InternetRequires a separate ISP (e.g., Earthlink) and an extra monthly ISP chargeUse when no computer netowrk is available or when it is necessary to bypass the facility’s network
71 Log in to WebAdvantageSurf toClick “Login” in the upper right hand corner
72 Log in to WebAdvantageEnter the user name and password supplied on the controller information sheet that was faxed to ACIClick “Sign in”
73 View On-Line Controllers View the list of all your accessible controllersGreen indicates an online unit, yellow indicates a unit in alarm, red indicates an off-line unit
74 Real Time MonitoringClicking the “View” button will allow you to view the controller’s real time data
75 Remote ProgrammingFrom the “View” mode, you also have full access to program the controller
76 Data HistorySelecting “History” from the summary screen allows you to view all the controller’s archived data.Select any sensor data or water meter readings
77 Auto-ReportingSetup your own summary report to be automatically ed at the interval of your choosing.Choose only the data you wish to receive.Copy the report to several recipients.
78 Auto-ReportingActual summary report ed by WebAdvantage
79 WebAdvantage Administration Using the administration function, assign controllers to groups and setup multiple usernames and passwords.