Transcript Fremont 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
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 toplevel 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:
• PVC with 3/4” tee
• PVC with 1” MNPT
SS bushing
• PVC with 1” quickdisconnect 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:
• 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)
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
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–
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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.
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
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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
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 offperiod (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
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
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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
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?
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 CAT5 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.