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 controllers
Specify the correct MegaTron model for you application
Determine 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 Towers
Boilers
Closed Loops
Process Streams
Commercial Pools/Spas
All in a single unit!

4. 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

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

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 programming
Factory - unlocks upgrades, new features, and top-level programming

7. Relay Outputs
MegaTron controllers can be equipped with up to V 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)

8. 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

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

10. 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

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 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

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 meters
5 low drum level inputs (single point)
1 flow switch input (thermal or mechanical)

13. 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

14. 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

15. 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

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 inputs
24 sensors (limited to 4 of each type)
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

18. 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.

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

20. 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

21. Notepad
Sample Notepad entry:

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 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.)

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 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!

25. 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)
………………...

26. 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

27. 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)
………………...

28. 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

29. 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
………………...

30. 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

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 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
……………………

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 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

33. 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

34. 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

35. 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

36. 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.

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 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)

41. 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)

42. 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)

43. 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.

44. 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)

45. 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

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 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

47. 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).

48. 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.

49. 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?

50. 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

51. 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.

52. 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.

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 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

56. 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)

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 formats
Connect to a MegaTron in both local and remote modes
Navigate the WebAdvantage interface
Understand 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 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).

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 data
Change all controller settings
Generate custom graphs and data logs
Receive automated summary reports via
Receive alarm conditions via

65. 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

66. 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

67. 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

68. 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

69. 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

70. 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

71. Log in to WebAdvantage
Surf to
Click “Login” in the upper right hand corner

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

73. 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

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

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

76. 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

77. Auto-Reporting
Setup 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-Reporting
Actual summary report ed by WebAdvantage

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