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Advantage Controls MegaTron, Installation, Maintenance And Repair Manual

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Advantage Controls MegaTron Installation, Maintenance And Repair Manual Download Page 8

8

Mounting Instructions

Select a mounting location that provides the operator easy access to the unit and a clear view of the 

controls through the cover of the controller. The location should be convenient to grounded electrical 

connections, the needed sample line plumbing and is on a stable vertical surface. 

WARNING: Avoid locations that expose the controller to direct sunlight, vapors, vibration, 

liquid spills or extreme temperatures; less than 0°F (-17.8°C) or greater than 120°F (50°C).  EMI 

(electromagnetic interference) from radio transmissions and electric motors can also cause damage 

or interference and should be avoided.

Electrode Installation

MegaTron controllers may come configured for various circulating water systems.  Listed below are 

instructions for cooling tower and boiler typical installations. Your specific installation requirements may 

differ but should conform to these instructions as much as possible for proper operation.

A.  

Cooling Tower 

The standard probe(s) and/or flow assembly for cooling tower installations is constructed of schedule 

80 PVC and supplied with 3/4” slip fittings for installing into a sample line.  To insure proper operation 

the sample line must have a flow rate of 3-10 gpm. Inlet pressure must be higher than outlet pressure in 

order for water to flow past the electrode(s) to achieve the required rate.  The probes are temperature 

compensated for increased accuracy. 

NOTES: 

  1.  

Install an isolation valve on either side of the flow assembly so electrodes can be    

 

easily isolated for removal and cleaning. 

  2.  

A line strainer is recommended upstream from the probes to protect against fouling  

 

and damage.

  3.  

Mount pH or ORP electrodes vertically.

  4. 

Green solution reference wire must be connected to either pH or ORP sensor. If both 

   

pH & ORP are present on system card, only one solution reference connection is 

  

needed. 

  5. 

Systems with a flow switch require 2-3 gpm flow rate to operate outputs.

WARNINGS:  

  1.  

Electrodes are O-ring sealed, which if damaged will cause a leak.

  2.  

Do not allow pH sensor tips to dry out, damage will occur.

  3.  

Do not exceed a water temperature range of 32°F to 140°F.

  4.  

Do not exceed a maximum pressure of 150 psi.

Summary of Contents for MegaTron

Page 1: ...gaTron Controller Installation Maintenance Repair Manual Advantage Controls P O Box 1472 Muskogee OK 74402 Phone 800 743 7431 Fax 888 686 6212 www advantagecontrols com email support advantagecontrols com 03 2017 ...

Page 2: ... 4 Electrical Wiring 4 Wiring Diagrams 5 Mounting Instructions 8 Electrode Installation 8 A Cooling Tower 8 B Boiler 10 III Front Panel Drawing 12 Description 12 IV System Operation Overview 13 Start Up 13 Calibration 13 V Menu Navigation 14 VI Maintenance 27 Electrode Cleaning Procedures 27 VII Troubleshooting 28 VIII Warranty 30 Day Billing Memo Policy 29 ...

Page 3: ...ndex must have pH W Auxiliary Flow Meter Inputs Y ETL Agency Listing Approvals Model numbers start MG followed by the Base System Control functions If multisystem all of the control functions of system one are followed by a dash then the functions for the next system If the next system s is the same as the one before a X2 X3 or X4 is used Another dash separates the whole unit options listed after ...

Page 4: ... after Bleed Activates the relay output based on a user defined percentage of time based on the bleed off another timer or digital input The relay is activated after a bleed cycle and runs for the set percentage of that bleed cycle 4 Percentage The relay is on for a percentage of a continuously repeating cycle time that can be set from 1 minute to 99 hours and 59 minutes 5 28 Day The timer is base...

Page 5: ...Rev B card use one of the other relays and program that relay to be controlled by the desired control function See page 24 3 The control function that activates each relay output is pre configured at the factory based on the options selected To change relay activation see on page 24 4 See page 30 for common bleed blowdown valve wiring 5 Refer to label inside lower panel cover for specific relay bo...

Page 6: ...card the second The 4 20mA output card will be the slot after the last active system card and the 4 20mA input card 2 after the last system card MegaTron Mother Board Relay Card Outputs 1 5 6 10 11 15 16 20 12 12 Incoming Power Display Ribbon Cable Connection Key Pad Ribbon Cable Connection Key Pad Ribbon Cable Connection Comm Sys 1 Processor Program Memory Card Connection Aux Meter Inputs 5 5 Car...

Page 7: ... Non isolated Configuration For non isolated 4 20mA outputs the controller will supply the power for the loop JP1 and JP2 must be jumpered and no connections are made to the Loop Supply points Note If multiple outputs are being connected to a single energy management system the negatives or commons MUST remain isolated from each other Does not apply to Rev D or later 4 20mA Input Card Wiring The 4...

Page 8: ...and or flow assembly for cooling tower installations is constructed of schedule 80 PVC and supplied with 3 4 slip fittings for installing into a sample line To insure proper operation the sample line must have a flow rate of 3 10 gpm Inlet pressure must be higher than outlet pressure in order for water to flow past the electrode s to achieve the required rate The probes are temperature compensated...

Page 9: ... Tower Probe Assembly Standard Tower Probes Conductivity E 4A pH PE 2 ORP OE 2 FS 0C FS FC FS SP or PE 21 OE 21 PE NUT pH Probe ORP Probe OR FS T TFS OC TFS C FS B1 SP Sample Valve E 30 PH 2C0A 150 UNION 3 4TT FS PT P Paddle Flow Switch used with option E3 E 30 PH 1A9A000262 ...

Page 10: ...e electrode is exposed to water and not steam Properly installed and adjusted this device will prevent flashing in the electrode chamber NOTES 1 Install a fully ported type valve between the electrode and the boiler This allows the electrode to be isolated for removal and cleaning 2 A flushing line and 1 4 turn type ball valve should be installed in the bottom of the cross to periodically flush se...

Page 11: ... bottom blowdown lines only continuous or surface blowdown lines Typical Timed Sampling and Sample and Hold Boiler Installation Throttling device approximately 18 past probe Electrode within a 1 cross with electrical connection vented 1 2 pipe between probe and throttle device and to the flush valve Electrically actuated blow down valve To drain Fully ported gate or ball valve 1 Continuous blow do...

Page 12: ...text options to find desired setting LEFT RIGHT Used to cycle through text or setting options to find desired setting SET UP RUN System initializes into RUN mode Press this key to put the controller in SET UP Mode and see HOME menu page ENTER Used to log a changed value into program HOME Used to go back to the HOME menu page CANCEL Used to cancel a pop up screen if no change is desired HELP Used t...

Page 13: ... temperature conductivity pH and ORP All units are shipped with the date preset and the clock set to your current time These readings and settings should be verified for accuracy and adjusted as per the instructions listed below 1 Conductivity To calibrate the conductivity reading remove the electrode from the line and wipe the flat surface with a clean cloth Re install the electrode and open the ...

Page 14: ...ring water meter totalizing RELAYS Menu for resetting accumulated ON times and manual activation 2 Set Points The same basic format is used for defining each available analog probe input s control parameters Boiler conductivity systems will also have an additional menu step for programming the sampling method desired from continuous timed or sample and hold SET POINTS For setting the relay set poi...

Page 15: ... makeup water BEST CYCLES Cycles desired with best water WORST MAKEUP Worst expected water WORST CYCLES Cycles with worst water SYSTEM MAX A fixed conductivity set point that overides the cycles setpoint if reached Note If continuous is selected the standard settings are used for system conductivity and the miscellaneous conductivity labeled M COND is the set points menus 2 3 pH and ORP The pH and...

Page 16: ...be continuously If the reading is above the set point blowdown will continue until the set point has been satisfied SET POINT What reading turns the relay on DIFFERENTIAL Amount reading changes by before the relay is turned off HIGH ALARM What reading generates a High alarm notification LOW ALARM What reading generates a Low alarm notification SAMPLE INT Period between samples SAMPLE DUR How long ...

Page 17: ... of the available analog probe inputs such as conductivity pH ORP or temperature 3 1 Conductivity Calibration CALIBRATE With a clean probe on line seeing the system s water enter the known tested from a calibrated hand held tester value RESET ZERO With the probe out of solution and dry enter a new zero point Note Probe must be dry NOTE In the calibration pop up window the raw analog to digital A D...

Page 18: ...external device match With a volt meter connected across the out and return wires see page 7 of the 4 20mA output channel to be calibrated go into the output s Low or High calibration The number displayed in the Calibration dialog box can range from 0 4095 with 800 equal to 0 mA output and 4030 equal to 20 mA This number range of 0 4095 is the raw digital to analog D A values and is strictly used ...

Page 19: ... 20mA input should be around 3750 and 4mA around 750 If the A D numbers are not in this range check input device The MAX and LOW calibration inputs are for telling the controller what to display for a 20mA input and a 4mA input For example if the input is a drum level sensor monitoring a 55 gallon drum the value for MAX should be 55 and LOW should be 0 The controller then displays a number automat...

Page 20: ...lons or liters from water meter to count before activating timer RUN TIME The amount of time for the timer to run METER INPUT Select water meter 1 or 2 for the timer s activation Water meter 1 2 can be selected only if the meters have the same contact value BLEED INTR Allows the pulse timer to be interrupted during conductivity bleed While interrupted you can also define the maximum number of time...

Page 21: ...hat the timer is to feed START The time of day for the timer to start RUN How long the timer is to run PREBLEED How long the controller is to bleed down before feeding in chemical NOTE The prebleed starts at the START time programmed above MIN COND The minimum conductivity that the unit will prebleed down to FEED LOCK Which other system timer to lockout during this timer s run time BLEED LOCK How ...

Page 22: ...r each system with ten notepad items The NOTEPAD is ideal for setting up and storing into the controller s history the items typically tested for reporting a service call The Notepad items come with no names but when an individual note is selected a menu for setting it appears Also can be used as a Reminder Timer with or without flow NAME Pick from a list of defined names or customize your own NUM...

Page 23: ...closed with flow FACTORY A factory only menu TEMP SCALE Set Celsius or Fahrenheit HISTORY Sets the history time stamp interval SYS INFO Tells unit software specifics 8 1 Password ADMIN PASSWORD The administrator password gives access to all menus except factory set up USER PASSWORD The user password allows the user to access HOME menus that are made available in USER SET UP ALARMS SYS 1 ALARMS SET...

Page 24: ...time of day that the daily water meter history cycle is to start ALARM DELAY The amount of time an alarm has to be on before it is recognized as an alarm 8 4 Flow Switch This menu allows the user to select if a flow switch signal will represent a flowing condition when a closed or open signal is seen for each systems flow switch input User can also select if timers can work always or only with flo...

Page 25: ...ple interval After the new sample interval has been set the onboard history is reset 9 1 Viewing History RELAY LOGS Relay activations displayed in a log form Arrow up to advance through the log ALARM LOG Alarm activations in log form SENSOR HISTORY For selecting the parameters and viewing of a given probe reading s history in log or graph form EVENT LOG Displays various activities 9 2 Notepad Entr...

Page 26: ...ter 400 million EVAP CALC Defines which way to subtract the 2 water meter inputs for an evaporation value 11 Relays STATUS Allows for viewing accumulated relay ON times temporary forcing relays ON or OFF or seeing which relay is on RESET Allows the accumulated run time of a particular relay to be reset to zero In the STATUS view the accumulated ON time is shown along with the main activator custom...

Page 27: ...e several ways to do this the preferred method being the one that is easiest for the user a Use a mild acid solution to dissolve deposits b Lay a piece of sandpaper 200 grit or finer on a flat surface such as a bench top Sand electrode to remove stubborn deposits Do not wipe surface with your finger Oil from your skin will foul carbon tips 5 Reinstall the electrode in the system After the reading ...

Page 28: ...on controller is designed for many years of trouble free operation Should a problem occur refer to the following chart to help identify the problem If replacement is required follow the procedures listed in the Warranty and Factory Service portion of this manual SYMPTOM POSSIBLE CAUSE SOLUTION False reading Bad or dirty electrode Clean as needed Out of calibration Calibrate unit Will not calibrate...

Page 29: ...ler malfunctions call 1 800 743 7431 provide our technician with Model and Serial Number information If they are unable to diagnose and solve your problem over the phone a fully warranted replacement will be shipped usually within 48 hours on a 30 Day Billing Memo This service requires a purchase order and the replacement is billed to your regular account for payment The replacement will be billed...

Page 30: ...30 Notes Common boiler blowdown valve connections ...

Page 31: ...31 Notes ...

Page 32: ...ment needs Cooling Tower Controllers Boiler Blow Down Controllers Blow Down Valve Packages Solenoid Valves Water Meters Chemical Metering Pumps Corrosion Coupon Racks Chemical Solution Tanks Solid Feed Systems Feed Timers Filter Equipment Glycol Feed Systems Pre Fabricated Systems Get the Advantage 5 4 3 2 1 ENTER HELP 5 4 3 CHANGE RUN SET UP 0 9 8 2 1 7 6 HOME BACK ...

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