Advantage Controls MegaTron Training Presented by:

Megatron Capabilities By the end of this session, you should be able to: Understand the core capabilities and features of the MegaTron line of controllers Specify the correct MegaTron model for you application Determine the list price of a specified MegaTron

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 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

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

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

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)

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

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

Sensor Inputs Cooling Tower Conductivity: Boiler 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 Boiler Conductivity: Ryton with 1” MNPT SS bushing All stainless body SS electrode tips Temperature compensation RTD (fast & accurate) Thermistor None

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 body With or without pre-amp ORP: 3/4” PVC tee (140*F) 3/4” CPVC tee (180*F) Tank mount (36” PVC) With or without pre-amp

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)

Thermal Flow Switches Megatron controllers are compatible with our thermal flow switches TFS use thermal sensors to detect flow status TFS don’t use mechanical floats TFS are resistant to debris in sample line TFS minimize incorrect flow readings

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

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

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)

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

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.

On-Board History Specify the data and measurement range of your on-screen graphs:

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

Notepad Sample Notepad entry:

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?

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.)

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!

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) ………………...

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

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) ………………...

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

Specification / Model Numbering Example #3: Build and price the following MegaTron: 3-tower system Conductivity and ORP control on each system 2 feed timers on each system Thermal flow switch on each system 4-20mA output for each probe Capability to add Internet communications in the future ………………...

Specification / Model Numbering Example #3: Build and price the following MegaTron: 3-tower system Conductivity and ORP control on each system 2 feed timers on each system Thermal flow switch on each system 4-20mA output for each probe Capability to add Internet communications in the future Model number = MGCRF2E1-X3-HO4 List price = $6200

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 probes Condensate monitoring using stainless steel pH probe 3 total feed timers (common feedwater tank) Stop input on each boiler to prevent sampling when offline (think flow switch) Internet communications via cellular modem ……………………

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 probes Condensate monitoring using stainless steel pH probe 3 total feed timers (common feedwater tank) Stop input on each boiler to prevent sampling when offline (think flow switch) Internet communications via cellular modem Model number = MGB1F3E6-B1E6-P8-H3 List price = $5141

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

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

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

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.

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.

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.

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.

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)

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)

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)

Alarms Menu Date/Time 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.

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)

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

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 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

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).

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.

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?

Megatron Hardware By the end of this session, you should be able to: Locate and identify the basic component parts of a MegaTron controller Understand the field-upgrade process Utilize the factory password to unlock extra features

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.

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.

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.

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).

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

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)

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).

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?

MegaTron Communications By the end of this session, you should be able to: Understand the various communication formats Connect to a MegaTron in both local and remote modes Navigate the WebAdvantage interface Understand the procedure for setting up automated summary reports

Connecting in Local Mode Connecting to a MegaTron in local mode allows you to: View real-time controller operating data Change all controller settings Download data as a delimited text file for importing into Excel Local mode is best used for simply downloading data from the MegaTron to your laptop (not many bells & whistles).

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).

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!

Connecting in Local Mode Local mode snapshot: East Village Hospital

WebAdvantage Overview WebAdvantage is an Internet-based remote monitoring service that allows you to: View real-time controller operating data Change all controller settings Generate custom graphs and data logs Receive automated summary reports via e-mail Receive alarm conditions via e-mail

WebAdvantage Overview Megatron controllers are online all the time allowing for continual transmission of data to the WebAdvantage servers Data is stored in duplicate on two servers to ensure it is always backed up WebAdvantage allows multiple users to connect to a controller simultaneously Constant connections allow a for a summary view of all controllers at once

WebAdvantage Requirements Before connecting to WebAdvantage, the following are required: Megatron with H1, H3, or H4 option Ethernet port, dedicated phone line, or SIM card from cellular provider Full-time Internet access (DSL, T1, dedicated dial-up, wireless plan) Internet browser with 128-bit encryption Login form supplied to ACI

Connecting to WebAdvantage Connection methods: RJ-45 Ethernet connection through building’s existing ISP (most common) - H1 On-board wireless modem - H3 On-board dial-up modem - H4

RJ-45 Through Ethernet Plug the supplied RJ-45 plug into an available CAT-5 Ethernet port Using DHCP protocol, the Megatron communicates with the facility’s computer network to obtain outside Internet access If desired, the building’s network administrator may wish to assign a static IP address in lieu of using DHCP Pros - easy setup, no extra ISP charge

Cellular Modem to Internet Insert the SIM card from your cellular provider into the cellular modem provided with the MegaTron Connect the external cellular antenna if necessary MegaTron will automatically connect to the Internet using the settings pre-programmed on the SIM card Requires 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

Dial-up Modem to Internet Plug the Megatron’s phone line cable into a dedicated phone jack Program the MegaTron with the ISP login information supplied by your provider and the MegaTron will establish a connection with the Internet Requires a separate ISP (e.g., Earthlink) and an extra monthly ISP charge Use when no computer netowrk is available or when it is necessary to bypass the facility’s network

Log in to WebAdvantage Surf to http://webadvantage.advantagecontrols.com Click “Login” in the upper right hand corner

Log in to WebAdvantage Enter the user name and password supplied on the controller information sheet that was faxed to ACI Click “Sign in”

View On-Line Controllers View the list of all your accessible controllers Green indicates an online unit, yellow indicates a unit in alarm, red indicates an off-line unit

Real Time Monitoring Clicking the “View” button will allow you to view the controller’s real time data

Remote Programming From the “View” mode, you also have full access to program the controller

Data History Selecting “History” from the summary screen allows you to view all the controller’s archived data. Select any sensor data or water meter readings

Auto-Reporting Setup your own summary report to be automatically e-mailed at the interval of your choosing. Choose only the data you wish to receive. Copy the report to several e-mail recipients.

Auto-Reporting Actual summary report e-mailed by WebAdvantage

WebAdvantage Administration Using the administration function, assign controllers to groups and setup multiple usernames and passwords.