Advantage Controls MegaTron Series User manual

MegaTron
Controller
Manual
Installation
Maintenance
HE-30
8/26/2002

MegaTron Combination Controller
Instruction & Maintenance Manual
Table of Contents
Contents Page No.
I. Introduction ....................................................................... 3
Model Numbering.............................................................. 3
Description of Unit............................................................. 3
II. Installation………………………………………………………5
Electrical Wiring ................................................................ 5
Wiring Diagrams………………………………………………6
Mounting Instructions ........................................................ 7
Electrode Installation......................................................... 7
A. Cooling Tower.......................................................... 8
B. Boiler........................................................................ 8
III. Front Panel
Drawing……..................................................................... 11
Description…………………………………………………….11
IV. System Operation Overview............................................. 12
Start-Up ....................................................................... 12
Calibration ……................................................................ 12
V. Menu Navigation .............................................................. 13
VI. Maintenance..................................................................... 20
Electrode Cleaning Procedures........................................ 20
VII. Troubleshooting ............................................................... 22
VIII. Warranty & 30 Day Billing Memo Policy........................... 23
Instructions herein apply to various MegaTron models. Some parts may not
apply to your specific model number. We have tried to include instructions
when it is necessary for any options which have been included in your unit.
2

I. Introduction
The MegaTron microprocessor based controllers are designed to provide a wide range
of control functions for recirculating water treatment systems. The controller is
programmed through a front panel keypad and can be configured to provide a
customized control system for your application. Your particular unit’s functions can be
determined be comparing the units model number to the Model Numbering Table (see
page 3).
☼Notice: Depending upon the options supplied on your unit you may or may not
have all features and functions described in this manual.
Model Numbering
MegaTron units have several base system control functions and unit optional features.
Your unit may be supplied with one or more of the features described in this manual. To
determine what features apply to your unit check the model number label located on the
controller enclosure.
Base System Control Functions Optional Features
C - Tower Conductivity Control A - Conduit connections
B - Boiler Conductivity Control D - Dry Contact relays
M - Make-up Conductivity H - Remote Communications bus only
P - pH Control H1- Direct Connect Communications
R - ORP Control H2- Internet Connect Communications
T- Temperature Control J- Additional System Card bus only
F1 to F5- Chemical Feed Timers K - Additional Control Relays
E - Flow Switch Assembly Y- ETL Agency Listing / Approvals
L1 to L5 - Drum Level Alarm Inputs
A model number will start with MG and will be followed with the Base System Control
functions. If the unit is a dual system, all of the control functions of system one are
followed by a dash then the functions for system two. If system two is the same as the
first a (–X2) is used. Another dash separates the optional features listed after all base
system control functions.
Example Model Number: MGCPF3E-X2-DHY
☼Note: This list represents our most popular options additional options codes are
available and may appear consult factory if any questions arise.
Description of Unit
MegaTron controllers may be configured to control one or two separate systems
including cooling tower and boiler applications and may have various features depending
on the model number. Whether the unit is controlling 1 or 2 systems each individual
system can be configured with a variety of the functions / features listed below and there
3

may be feature differences between the two systems on a unit with two systems. (See
model numbering table on page 3.)
Control Functions
Each of these control functions are based on an analog input from a probe and will
include user settable relay control settings along with a High and Low Alarm setting and
Limit Timer. Each control function will include a control relay output. When the reading
reaches the Set Point the control relay is activated until the reading changes by the
Differential amount.
1. Conductivity – The conductivity function of the controller is designed to monitor
and control Total Dissolved Solids (TDS) in a recirculating system like a cooling
tower or boiler in terms of electrical conductivity measured in MicroSiemens/cm.
This control function is also referred to a Bleed. Units with conductivity and the
make-up conductivity function can control the TDS of the tower system by
calculating the difference between the incoming make-up water’s conductivity
and the system’s conductivity.
2. pH – The pH function monitors and controls pH on a scale of 0-14 pH units.
3. ORP – The ORP function monitors and controls ORP on a scale of +/- 1000 mV.
Chemical Feed Timers
Chemical feed timers are designed to automate the addition of various chemicals by
activating a relay output. Multiple timers can be supplied depending upon the model
number and each timer will include a relay output. All timers can be programmed to be
one of the following types.
1. Pulse Time – This timer accepts pulses from a make-up water meter (supplied
separately). It can accumulate 1-99 pulses to the activate the timer to run from
0-99 minutes in minutes and seconds.
2. Feed with Bleed – This timer activates the relay output simultaneously with the
bleed. This timer limits the amount of time the relay output will be on during the
bleed cycle, thereby preventing chemical overfeed.
3. Feed after Bleed- This timer activates the relay output based on a user defined
percentage of time the bleed off. 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. Both the percentage and cycle time are programmable.
5. 28 Day – The timer is based on a 28 day cycle with two independent
programmable feed cycles with prebleed and bleed lockout settings.
4

II. Installation
Electrical Wiring
The MegaTron controller has an internal regulated fused power supply that will operate
off of 90 to 250 VAC at 47 to 63 Hz on the incoming wiring. Each output relay is
individually protected with a replaceable fuse. Relay outputs will equal incoming line
voltage.
☼WARNINGS:
1. The controller should be connected to its own isolated circuit breaker and
for best results the ground should be a true earth ground not shared.
Wiring must be done according to all applicable local codes.
2. Power (line voltage) must be disconnected while making any connections.
If power is supplied to the unit, line voltage will be present on the relay
cards located in the lower section of the enclosure, even with the power
(ON/OFF) switch off.
3. Low voltage signal wires (probes, flow switch, water meter etc…) should
never be run in conduit with high voltage wires.
☼NOTE: Liquid tight fittings and some labeled signal leads are provided for all
signal (low voltage) connections for both pre-wired and conduit units.
Pre-Wired
Pre-wired units are supplied with a 16 AWG cable with 3-wire grounded USA 115 volt
plug for incoming power and 3-wire grounded receptacle cords for all control relay
outputs also 16 AWG.
Conduit
Conduit units are predrilled at the factory and supplied with conduit knockouts for easy
hard wiring to supplied detachable connectors on the relay card(s) located in the lower
section of the controller. Remove the six screws of the lower panel for access.
☼NOTES:
1. Relay 1 and 6 (if supplied) only provide a normally open (N.O.) relay output.
If a N.O. and normally closed (N.C.) are required for a specific control
function use one of the other relays and program the selected relay to be
controlled by the desired control function. See relay configure set up on
page 18.
2. What control function that activates each relay output is pre-configured at
the factory based on the options selected on your controller. To change
what activates a given relay see relay configure set up on page 18.
5

Relay Card Diagram
System Card Wiring
Units are provided with all low signal wires (probe, water meter, flow …) pre-wired with
labeled cables coming out of the controller. If it is desirable to wire directly to the system
cards the following diagram indicates all connection for each system card.
☼WARNING: This procedure is not recommended since it requires removal of the
front panel.
6

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 ¾” 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 electrodes vertically.
4. Units with a flow switch require the needed flow rate to operate the relay
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.
7

pH and/or
ORP Probe
Conductivity Probe
TE-4A PE-2 or OE-2
Typical Cooling Tower Installation Diagram
B. Boiler
Standard boiler electrodes (part # BE-4BC) have a 1” MNPT stainless steel bushing and
are supplied with a 1”FNPT cross designed for mounting in the skimmer (surface)
blowdown line. Sampling of the boiler’s water can be achieved using one of two typical
plumbing configurations (continuous sampling or timed and/or hold sampling). For a
8

successful installation, it is critical to observe the recommended distances and pipe
sizes provided in the installation drawings. The probes are temperature compensated
for increased accuracy.
For best results, the electrode cross should be mounted on a 1"skimmer blowdown line
within 4' of the boiler. Smaller line sizes and greater distances may affect the response
time and accuracy of the electrode. A flow-throttling device down stream from the probe
(within 12-24 inches) is required to ensure that the 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" sediment from the electrode
chamber.
3. Make sure the alignment arrows on the probe end up parallel to the flow
for best performance.
☼WARNINGS:
1. The probe must be fully immersed in the system water to read correctly.
Steam flashing will result in incorrect readings.
2. Do not exceed a maximum water temperature of 400˚F.
3. Do not exceed a maximum pressure of 300 psi.
4. A throttling device must be installed down stream from the probe.
BE-4B
Boiler
Conductivity
Probe
9

Typical Continuous Sampling Boiler Installation Diagram
Typical Timed Sampling and Sample and Hold Boiler Installation
10

Front Panel Description
NUMBER Keys- Used to enter new values in the SET UP mode and to access
desired sub menus.
UP/DOWN - Used to cycle through 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 switch to put the
controller in SET UP Mode and see HOME menu page.
ENTER Key - Used to log a changed value into program.
HOME Key - Used to go back to the HOME menu page.
CANCEL Key - Used to clear values keyed in that are not wanted.
HELP Key- Used to access help screens.
BACK Key - Used to go back to last menu screen viewed.
11

IV. System Operation Overview
Operation
MegaTron controllers have two modes of operation, RUN and SET-UP.
RUN - This mode is for normal operation. In the RUN mode the display will show each
system's parameters. If an alarm is present the ALARM box will flash how many alarms are
present. No settings may be entered or changed in the RUN mode.
☼NOTE: Readings are updated every 6 seconds on the screen while in the RUN mode.
SET-UP - This mode is used to make adjustments to settings and readings on the controller.
To access the SET UP mode from the RUN screen, press the SETUP/RUN key.
Typical Start Up Instruction
Complete all installation steps before beginning this procedure. Ensure that all
controlled devices (pumps, solenoid valves, etc.) are operational and connected to the
controller. Open the isolation valves to allow water to pass through the sample stream
assembly.
Before beginning the start up procedure, familiarize yourself with the programming and
operation of the system by reviewing the menus available. Use the keys of the controller
to skim through all your options.
A. Calibration
All MegaTron controllers are factory calibrated for 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.
An accurate temperature reading is critical to a good conductivity reading as the
temperature compensation factor is approximately 1% per degree F.
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 isolation valves to allow a sample across the probe. Be sure to allow the
reading to stabilize for one minute. Select "SYSTEM COND" from the
"CALIBRATION" menu. Then key in the corrected conductivity value. Press
ENTER to log in that reading.
2. pH - Under normal operating conditions, pH calibration is achieved using the
following steps. From the "CALIBRATION" menu, select "SYSTEM PH." Enter the
correct pH value. Press ENTER to log in the new reading.
3. ORP - To calibrate ORP, from the CALIBRATION menu select "SYSTEM ORP".
Compare the displayed reading to the actual system ORP. If these readings do not
12

match, key in the correct ORP value, and push ENTER. Press the SETUP/RUN
key to resume normal operation.
There are limits to how much the calibration can be adjusted. The instrument will only
accept new conductivity values which are from 1/2 to 2x the present reading. Any entry
outside this range will cause a default to the original reading. If this happens, call 1-800-
743-7431 for technical assistance.
V. Menu Navigation
To access the menus press the Set Up / Run key on the front panel. This takes you to the
Home menu. MegaTron controller’s menus are easily navigated by selecting your desired
menu move by pressing the associated number key next to a menu box on the screen.
Once you have stepped through the sub menus to reach a point at which a value or
selection is made a Pop-up window will appear prompting you to enter a desired value or
selection.
☼NOTE: When entering new numeric values, enter all available digits (characters).
1. Home Menu
From the HOME menu select the desired menu.
The menu name explains what parameters can
be programmed in the menu.
>HOME SETUP<
SETPOINTS DATE/TIME
CALIBRATION CONFIGURE
TIMERS HISTORY
CUSTOMIZE WATER METER
ALARMS RELAYS
SET POINTS - Setting control set points for conductivity, temperature, pH and ORP.
CALIBRATION - Calibrating conductivity, temperature, pH and ORP if present.
TIMERS - Menu for selecting type and settings for all present feed timers.
CUSTOMIZE - Giving the controller, each system and all relays a user defined name.
ALARMS - View current alarms.
DAY/TIME - Menu for setting date and time.
CONFIGURE - Menus for configuring passwords, relay activations, digital inputs, setting
history interval, flow switch, contrast, temperature scale.
HISTORY - Allows for view history on board in a graph form.
WATER METER -Menu for configuring water meter totalizing.
RELAYS - Menu for resetting accumulated "ON" times and manual activation.
13

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 points
for the available analog probe readings such
as conductivity, pH, ORP or temperature.
If there is more than one System present you
first select which system’s values are to be
adjusted.
>SYSTEM 1 SET POINTS<
SYSTEM COND
SYSTEM TEMP
SYSTEM Ph
SYSTEM ORP
2.1 Set Point Options
SET POINT – What reading turns the relay on
>SYSTEM 1 COND SETPOINT <
SET POINT
DIFFERENTIAL
HIGH ALARM
LOW ALARM
LIMIT TIME
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.
LIMIT TIMER- What amount of continuous
bleeding will generate a time alarm notice.
3. Calibration
Calibration is for adjusting the unit’s displayed value of a probes reading to match your tester or known
solution.
>SYSTEM 1 CALIBRATION<
SYSTEM COND
SYSTEM TEMP
SYSTEM Ph
SYSTEM ORP
CALIBRATION – For adjusting the actual
reading values of the available analog probe
inputs, such as conductivity, pH, ORP or
temperature.
3.1 Conductivity Calibration
>SYSTEM 1 COND CALIBRATION<
CALIBRATE
RESET ZERO
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!
14

3.2 pH and ORP Calibration
>SYSTEM 1 pH CALIBRATION<
1 POINT CAL
2 POINT CAL
1 POINT – With a clean probe on-line seeing the
system’s water enter the known (tested from a
calibrated hand held tester) value.
2 POINT – Enter a known Low value with a
clean probe in a buffer solution. Then enter a
known High value with the clean probe in a
buffer.
☼Notes: 1. Probes must be rinsed between buffers when doing a 2 Point calibration and given at
least 30 seconds in solution to adjust to the buffer.
2. There must be at least 2 full pH points between buffer solutions. Using a buffer of 4
and 10 is the best procedure. ORP buffers should be at least 200 points apart.
4. Timers
A unit may have up to 5 selectable timers for each system on a controller. All timers are associated
with their system, so for a % of post bleed timer looks at the bleed of that system.
>SYSTEM 1 TIMERS<
TIMER 1
TIMER 2
TIMER 3
TIMER 4
TIMER 5
TIMERS – Select the type (28-day, pulse, limit,
percent or percent of post blowdown) as well as
the run times of each timer available per system.
4.1 Timer Type Selection
A pop-up screen lets you scroll through the various timer types available.
>SYSTEM 1 TIMER 1 SET UP<
SET UP TIMER TYPE
>SET TIMER TYPE (PULSE)<
->PULSE
USE UP/DOWN KEYS TO CHANGE
PRESS ENTER TO ACCEPT
Pulse- A water meter activated timer
Limit – Feed with bleed with a maximum run
time or limit for one bleed cycle.
Percent – A continuous cycle timer that sets a
percentage On time of a cycle.
Percent Post Bleed – For feed after bleed for a
settable percentage of the bleed time with a
maximum run time.
28-Day – A biocide or event timer.
4.2 Timer Set Up
Each timer type selected will have its own unique Set Up sub menu with additional selections
specific to the type of timer selected. The page displayed before entering the Set Up menu of a
timer provides an overall review of the timers current settings.
>SYSTEM 1 TIMER 1 SET UP<
TIMER TYPE: PULSE
PULSES: 10
RUN TIME (MM:SS): 01:00
INPUT: WATER METER 1
TIMER TYPESETUP
15

4.3 Pulse Timer
PULSES- The number of contacts from water
meter to count be activating timer.
>SYSTEM 1 TIMER 1 CHANGE<
PULSES
RUN TIME
METER INPUT
RUN TIME-The amount of timer for the timer
to run
METER INPUT-Since each system with
timers has two water meter inputs you must
select which meter to get contacts from.
4.4 Percent Timer
>SYSTEM 1 TIMER 1 CHANGE<
% OF CYCLE
CYCLE TIME
% of CYCLE- The percent of the defined cycle
timer that the timer is to be on.
CYCLE TIME-The amount of time in MM:SS that
the cycle is going to be.
4.5 Post Bleed Timer
>SYSTEM 1 TIMER 1 CHANGE<
% OF BLEED
LIMIT TIME
% of BLEED- The percent of the post
conductivity bleed time that you want the timer
to run.
LIMIT TIMER- The limit timer is a safety feature
that limits a single feed cycle to the amount of
timer set regardless of the calculated post feed
%.
4.6 With Bleed Timer
>SYSTEM 1 TIMER 1 CHANGE<
LIMIT TIME
LIMIT TIMER- This timer starts when the
conductivity bleed starts and turns off when the
bleed stops or until the limit time has been
reached. The time can be set in MM:SS.
16

4.7 28-Day Timer
Each 28-day timer has a Program 1 and a Program 2 for programming the various feed times.
The programming for Program 1 and 2 are the same but allow for more variation in the timer’s
relay activation.
WEEKS- The week(s) that the timer is to feed.
DAYS- The day(s) that 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.
>SYSTEM 1 TIMER 1 CHANGE<
WEEKS MIN COND
DAYS FEED LOCK
START TIME BLEED LOCK
RUN TIME FLOW LOCK
PREBLEED
MIN COND-The minimum conductivity that
the unit will prebleed down to.
FEED LOCK-Which other system timer to
lockout during this timers run time.
BLEED LOCK-How long to lock out the
bleed function after the timer’s run time.
FLOW LOCK-If the system has a flow
switch you can ignore it for this timer.
5. Customize
>CUSTOMIZE<
UNIT NAME
SYS 1 NAME
SYS 2 NAME
RELAY NAMES
CUSTOMIZE – Allows for the user to define the
on-screen name for the Unit, System 1 and
System 2 (if applicable) as well as the names for
each relay.
6. Alarms
ALARMS – Shows any current alarms.
>ALARMS<
SYS 1 ALARMS
SYS 2 ALARMS
7. Date and Time Set Up
>SET DATE AND TIMES<
SET DATE
SET TIME
SET DAY
SET WEEK
Friday May 18, 2002 03:04:56
DATE AND TIME - For setting the date,
time, day and week on the controller.
17

8. 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.
INPUTS- This screen shows what digital
inputs are available on the unit such as water
meters, flow and drum level alarms.
CONTRAST- This screen allows for adjusting
the display contrast.
FLOW SW- Defines a flow switch to be open
or closed with flow.
FACTORY- A factory only menu
TEMP SCALE- Set between Celsius or
Fahrenheit
>CONFIGURE<
PASSWORD CONTRAST
RELAYS TEMP SCALE
INPUTS NETWORK
HISTORY SYS INFO
FLOW SW FACTORY
HISTORY – Sets the history time stamp
interval.
SYS INFO- Tells unit software specifics.
8.1 Password
>CONFIGURE PASSWORDS<
ADMIN PASSWORD
USER PASSWORD
USER SET UP
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.
8.2 Relays
>CONFIGURE RELAYS<
RELAY 1
RELAY 2
RELAY 3
RELAY 4
RELAY 5 MORE RELAYS
CONFIGURE RELAYS – This menu lets
you choose what available function (timer 1,
conductivity, alarms etc…) activates a
particular relay. When you select a relay a
pop-up screen appears with a list of all
available activation functions to arrow
through.
8.3 Network
NETWORK – This menu is used for setting
up the remote WebAdvantage
communications and is covered in a
separate manual.
>CONFIGURE NETWORK<
IP ADDRESS HTTP REMOTE
IP MASK FTP
GATEWAY RESET
SERVER
HTTP LOCAL
18

9. History
The onboard history allows for viewing the history of the probe readings, relay activations,
key pad activity, calibrations and alarm logs for each system present. An initial overview
page is displayed showing your current sample interval, the calculated number of days the
unit can keep probe history for before loosing the oldest. The number of sensor samples
and relay/alarm events currently stored is also displayed.
Note: The history can be reset by going to
the configure menu and entering a different
sample interval. After the new sample
interval has been entered you can then re-
enter your desired sample interval.
>HISTORY REVIEW<
SYSTEM 1 Sample Time: 5 MIN
(Length 164.62 days)
Sensor Samples
882
Relay/Alarm Events
323
9.1 Viewing History
RELAY LOGS- Relay activations displayed
in a log form. Arrow up to advice through
the log.
>HISTORY<
RELAY LOGS
ALARM LOGS
SENSOR HISTORY
EVENT LOG
ALARM LOG- Alarm activations displayed
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 keypad
activities.
10. Water Meters
WATER METERS – Shows the water meter
input records (totalizer) and defines the contact
value (100) and units of measure (gallons).
>WATER METERS<
SYS 1 WATER METER 1
SYS 1 WATER METER 2
SYS 2 WATER METER 1
SYS 2 WATER METER 2
11. Relays
>RELAYS<
RELAYS 1-10 STATUS
RELAYS 1-10 RESET
STATUS– Allows for viewing accumulated relay
ON times, forcing relays ON or OFF or seeing
which relay is on.
RESET- Allows for the resetting to zero the
accumulated run time of a particular relay.
19

VI. Maintenance
The only required maintenance for normal uninterrupted operation of your MegaTron
controller is cleaning of the electrode(s).
After initial start up, it is a good idea to clean the electrode frequently until a schedule
based on need has been developed. Since each application is unique, it is difficult to
estimate the required frequency of cleaning. The first cleaning should take place after
about one week of the system being on line.
To determine the required cleaning frequency, record the reading on the controller
before the electrode is removed for cleaning. After cleaning, record the new reading. If
a change is observed in the two readings, the electrode was dirty. The more significant
the change, the dirtier the electrode. If no change occurs, cleaning needs to be done
less often.
Conductivity Electrode Cleaning Procedure
1. Record the current conductivity reading.
2. Turn off water flow through the electrode loop, bleed pressure from the line and
remove electrode.
3. Use a clean cloth and a mild cleaning solution to remove loose dirt etc., from the
flat surface of the electrode.
4. If the electrode has deposits such as scale attached to the electrode surface a
more aggressive cleaning approach will be needed. There are 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 stabilizes, calibrate the
unit to a reliable test reading.
Many times an electrode can appear to be clean, but the unit still cannot be calibrated. If
this is the case, use one of the more aggressive electrode cleaning procedures listed in
step 4 above. Recheck the calibration after completion of this procedure. If no change
was observed in the reading, replace the electrode. If a change occurred but the unit
still will not calibrate, repeat procedure as many times as necessary.
pH and ORP Electrode Cleaning Procedure
1. Remove the pH electrode from the system by turning counter-clockwise until fully
released.
20