MegaTron BlueTrak Supplement

Manual
MegaTron
Controller Supplemental
BlueTrack
Instructions
Notice: This manual includes instructions for the BlueTrack that is not
covered in the main MegaTron manual but will refer to items covered
in the main 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
4/2010
MegaTron Controller
BlueTrack Option “U” Manual
Table of Contents
Contents
Page
I.
Introduction......................................................................................... 2
Description of Option “U”.................................................................... 3
Electrical Wiring.................................................................................. 3
II. Operation............................................................................................ 4
A.
Customize................................................................................. 4
B.
Configure.................................................................................. 4
C. Set Points................................................................................. 5
D. Calibration................................................................................ 6
Troubleshooting.................................................................................. 7
III. I.
Introduction
Advantage Controls’ BlueTrack controllers are designed to monitor and control the concentration of the
BlueTrace organic colorant in a recirculating cooling water system. This colorant, available from ProChemTech,
is blended with cooling water treatment chemicals at a very precise ratio. By measuring the amount of
BlueTrace colorant, we are able to infer the amount of cooling water treatment present in a system.
BlueTrack sensors use a custom LED and photoreceptor to measure the transmittance of light through a
solution containing the BlueTrace colorant. The sensor outputs a variable 0-5 VDC signal based on the level
of light that is transmitted through a solution. This 0-5 VDC signal is sent to a MegaTron or MegaTron SS
controller equipped with option “U” (0-5 VDC input).
There is an inverse relationship between BlueTrace concentration and BlueTrack voltage output. Higher
concentrations of BlueTrace in a sample will decrease the amount of transmitted light and will yield a lower
voltage output, while lower concentrations of BlueTrace will allow more light to pass through the solution
and yield a higher voltage output. The following chart represents the relationship between BlueTrace
concentration, absorbance (impedance to light transmittance), and voltage output:
BlueTrace Concentration
0.0 ppm
1.0 ppm
2.0 ppm
Absorbance
0.00
0.08
0.16
BlueTrack Voltage Output
5.00 V
4.17 V
3.38 V
To simplify this inverse relationship, we invert the 0-5 VDC output scale so that higher levels of BlueTrace
chemical correspond to a higher percent reading on the MegaTron. The controller displays 100-%T. You
can convert % transmission to absorbance with the equation A = 2 - log10%T.
% Transmittance
Absorbance
Description of Option “U”
MegaTron controllers with option “U” may have one to eight 0-5 VDC inputs. The 0-5 VDC inputs will operate
similarly to a 4-20mA input and use the same basic menu in the MegaTron. When used with a BlueTrack
sensor, a 0-5 VDC input from the BlueTrak sensor can be used to activate a relay based on a set point for
automatic feed of BlueTrace chemicals.
Electrical Wiring
If a BlueTrack sensor is ordered with a MegaTron it will be prewired to the 0-5 VDC input card using low
voltage.
MegaTron 0-5 VDC Card Non-Isolated
GND
GND
GND
GND
GND
GND
GND
Black & Green
GND
BlueTrack
Probe
White
Red
MegaTronSS 0-5 VDC Card Non-Isolated
0-5 VDC Input
Card for SS
MegaTron
0-5 VDC Input
Non-Isolated
J1
Input 1
J3
Input 2
IN-8
IN-7
IN-6
IN-5
IN-4
IN-3
IN-2
IN-1
+12V
+12V
+12V
+12V
+12V
+12V
+12V
+12V
J4
Input 3
Note: Use 22 AWG
(.76 mm) twisted
pair shielded wire
for all of these low
voltage signal
connections.
LED
Ground
Signal
+12 VDC
II.
Operations
The MegaTron’s BlueTrack control circuit is designed maintain a precise level of BlueTrace in the recirculating
cooling tower water by monitoring the BlueTrace level and activating a relay output as the BlueTrace level
falls. As such, the MegaTron is programmed with a “falling” setpoint. There are four MegaTron menus that
relate to customizing, calibrating, and programming the BlueTrack sensor.
Units with a 0-5 VDC input option “U” will have the following menus to program for controlling with a BlueTrack sensor.
A.
Customize
This menu allows the user to define the on-screen name of the unit plus the name of each system and relay.
The user can also setup a 0-5 VDC input name and unit of measurement.
>CUSTOMIZE<
UNIT NAME
RELAY NAMES
NOTEPAD
SYSTEM 1 NAME
pH INDEX
SYSTEM 2 NAME
0-5 IN
RUN SCREEN
Note: When entering values for custom names
use the numerical keys for numbers and the up /
down arrows to scroll through all the characters
of a key board. Press the right arrow to advance
the curser after setting a desired value. Press the
Help button to place the last entered character
into the new cursor space to speed up the
process. The Help button will also jump advance
through the characters.
>0-5 INPUT 1 CUSTOMIZE<
NAME
UNITS
NUMBER
NAME - Customize the name of the input.
UNITS - Set the units of measurement. MegaTron
will display the BlueTrack reading in a 0-99.99%
range, so the default units are set as “%”.
NUMBER - Set the number range. Since the
BlueTrack range will be 0-99.99%, the number
format should be expressed as XX.XX.
B.
Configure
Provides access to menus to set-up passwords, relay activation, temp scale, display contrast, flow switch,
inputs, history time stamps, factory set-up and system information. User will need to go here to configure a
relay to be activated by the 0-5 VDC input in the Relays sub menu of Configure.
CONFIGURE RELAYS - This menu lets you
choose a Main Action or function (timer 1,
conductivity, alarms etc...) to activate a relay.
>RELAY 1 SETUP<
MAIN ACTION
DISABLE 1
ACTIVATOR 2
DISABLE 2
ACTIVATOR 3
DISABLE 3
ACTIVATOR 4
DISABLE 4
DAILY MAX
A pop-up screen appears with a list of all
available activation functions to arrow through
and the 0-5 VDC input will need to be selected
as the main activator.
The MAIN ACTION setting should be assigned to MA IN1 (or 0-5 VDC IN1 depending on firmware version)
using the up and down arrow keys followed by the ENTER key. This tells the MegaTron that the relay will be
activated by the BlueTrack sensor (0-5 VDC input).
In the same way, ACTIVATOR 2-4 can be used to activate the same relay for advanced control schemes.
Likewise, DISABLE 1-4 can be used to deactivate the BlueTrace relay output based on up to four different
user-defined events (e.g., no flow, oxidizer feed, etc.). DAILY MAX ensures that the BlueTrack relay does
not activate for more than XX hours in a single 24-hour day (beginning & ending at midnight).
Note: A no flow disabler should be set if the sytem has a flow switch and you do not want to feed BlueTrack
during a no flow condition. A disabler during biocide feed may also be desired.
C.
Set Points
The setpoints menu is used to program the BlueTrack readings at which the corresponding relay output will
be activated and deactivated along with any applicable alarm limits.
SETPOINT - BlueTrack reading (00.00-99.99%)
at which the relay output will activate.
The
setpoint should be set as a FALLING setpoint
as indicated in the pop-up programming box. If
it displays RISING, press the right arrow key to
change. Next, use the number keys to enter the
appropriate setpoint
>0-5 INPUT 1 SETPOINT<
SET POINT
DIFFERENTIAL
HIGH ALARM
LOW ALARM
LIMIT TIME
DIFFERENTIAL (or deadband) - Increase in the BlueTrack reading above the setpoint that must occur
before the relay output deactivates. For example, to maintain a BlueTrack control range of 15.00 to 15.50,
set the setpoint at 15.00 and the differential at 00.50.
HIGH ALARM and LOW ALARM - Independently adjustable settings for high and low alarm to provide an
alert with the BlueTrack reading is above or below these boundaries. These alarms have no effect on the
relay output unless they have been programmed as relay disablers.
LIMIT TIME - Prevents the accidental over-feed of BlueTrace product by limiting the relay run time during a
particular relay activation cycle. This setting is adjustable in hours & minutes (HH:MM). The limit time alarm
will disable the relay output until the BlueTrack setpoint is satisfied, or until the limit timer is changed to a new
value. For this reason, the limit timer should be programmed for a value that is significantly longer than the
expected normal run time for the control relay to prevent premature deactivation. DO NOT SET THE LIMIT
TIME TO A VALUE OF 00.00 OR ELSE THE RELAY WILL NOT ACTIVATE.
D.
0-5 VDC Input Calibration
The MegaTron’s CALIBRATION menu allows you to calibrate the 0VDC and 5VDC span points and program
the corresponding BlueTrack readings for these upper and lower limits. THIS MENU IS ONLY USED TO
SET THE FULL SCALE 0VDC AND 5VDC LEVELS AND SHOULD NOT BE USED TO CALIBRATE THE
BLUETRACK SENSOR. 0-5 VDC inputs can be calibrated to insure that the input seen by the controller
from the external device match. It also allows for setting the 0-5 VDC input into a number range that relates
to the value being read.
>CURRENT LOOP CALIBRATION<
Select the Input to be calibrated
INPUT 1
INPUT 2
>INPUT 1 CALIBRATION<
5VDC14500
0VDC 2900
MAX
200
MIN
0
>0-5 INPUT 1 CALIBRATION<
INPUT 1 5VDC CAL
14500 A/D
PUT 5VDC ON INPUT THEN
PRESS ENTER
5VDC - Allows you to calibrate the 5VDC input level. This input is already calibrated at the factory, but if it
ever needs to be recalibrated, a voltage simulator must be connected to circuit ground and the +VDC input
on the 0-5 VDC card. Once the simulator is in place, adjust the simulator to generate a +5VDC signal.
DO NOT ACCESS THIS MENU UNLESS DIRECTED TO DO SO BY TECHNICAL SUPPORT.
0VDC - Just like the 5VDC menu, except this setting allows you to adjust the 0VDC input level. The same
calibration procedure can be followed, except using a simulated 0VDC signal to calibrate the input. DO
NOT MAKE ANY ADJUSTMENTS TO THIS SETTING UNLESS DIRECTED TO DO SO BY TECHNICAL
SUPPORT.
MAX - Assigns the BlueTrack reading that corresponds to a 5VDC input. Recall from the overview that
there is an inverse relationship between the BlueTrace reading and the BlueTrack sensor voltage output.
Therefore, the MAX reading should be entered as 00.00.
MIN - Sets the BlueTrack reading that corresponds to the 0VDC input. On a 0-100% scale, this should be
programmed as 99.99.
If calibration of the sensor is required, there is a calibration pot labeled R6 on the circuit board located behind
the protective rubber cover on the sensor. To calibrate the sensor, simply adjust this calibration pot up or
down so that the MegaTron’s BlueTrack display on the run screen corresponds to the desired percentage
value.
Sample Board
Remember, the MegaTron is actually reading “100 - % transmittance”, so use the chart shown in the overview
section to calibrate the MegaTron’s reading to match the corresponding absorbance value. For example, if a
hand held test reveals absorbance of 0.10 (79% transmission), calibrate the sensor so that the display reads
21% (100-79).
III.
Troubleshooting
BlueTrack controller not reacting to changes in chemical (dye) levels
Before you try to check the DC voltage output with a voltmeter, make sure the following settings are
correct:
1. CUSTOMIZE 0-5 IN NUMBER XX.XX (make sure number format is expressed as XX.XX – if not, use up
or down arrows to change)
2. CALIBRATION 0-5VDC IN INPUT 1 MAX 00.00
3. CALIBRATION 0-5VDC IN INPUT 1 MIN 99.99
4. SETPOINTS 0-5VDC INPUT 1 SETPOINT make sure setpoint direction is set to FALLING (relay will
activate as reading falls below the setpoint)
If the problem persists after ensuring the settings are correct, disconnect the white and black wires from
the 0-5VDC input card in the MegaTron SS (see page 3 in the attached manual) and check the DC voltage
output with a voltmeter (white = positive, black = negative). The DC voltage should be between 0 and 5
VDC. Next, rotate the sensor calibration pot to increase or decrease the DC voltage output. The calibration
pot is located on the sensor circuit board behind the grey rubber cover on the sensor housing (labeled R6
as shown on page 7 of the attached manual). If the voltage doesn’t change at all after rotating the pot a few
turns in either direction, the sensor is faulty and needs to be replaced. If you do get a change in voltage
while rotating the calibration pot, it’s possible that the sensor was far out of calibration and just needed to
be brought back into range. To verify, reconnect the sensor wires and calibrate the sensor to the desired
reading per the table on page 2 in the attached manual. It’s also possible that the 0-5VDC input card is bad
if you can measure a voltage change from the sensor, but see no change on the MegaTron SS display when
the wires are connected.
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